Piezo sensor for a power source

ABSTRACT

An aerosol delivery device includes a power source and an aerosol production component that is powerable to produce an aerosol from an aerosol precursor composition. The aerosol delivery device also includes processing circuitry configured to switchably connect the power source to a load that includes the aerosol production component and thereby power the aerosol production component. A piezo sensor is operatively coupled with the power source and the processing circuitry. The piezo sensor is configured to generate an electrical response to a deformation of the power source, and the electrical response is indicative of a characteristic of the deformation. The processing circuitry is configured to control the aerosol delivery device based at least in part on the characteristic of the deformation indicated by the electrical response.

TECHNOLOGICAL FIELD

Some embodiments of the present disclosure relate to aerosol deliverydevices such as smoking articles that produce aerosol. The smokingarticles may be configured to heat or otherwise dispense an aerosolprecursor or otherwise produce an aerosol from an aerosol precursor,which may incorporate materials that may be made or derived from tobaccoor otherwise incorporate tobacco, the precursor being capable of formingan inhalable substance for human consumption.

BACKGROUND

Many smoking articles have been proposed through the years asimprovements upon, or alternatives to, smoking products based uponcombusting tobacco. Some example alternatives have included deviceswherein a solid or liquid fuel is combusted to transfer heat to tobaccoor wherein a chemical reaction is used to provide such heat source.Additional example alternatives use electrical energy to heat tobaccoand/or other aerosol generating substrate materials, such as describedin U.S. Pat. No. 9,078,473 to Worm et al., which is incorporated hereinby reference.

The point of the improvements or alternatives to smoking articlestypically has been to provide the sensations associated with cigarette,cigar, or pipe smoking, without delivering considerable quantities ofincomplete combustion and pyrolysis products. To this end, there havebeen proposed numerous smoking products, flavor generators, andmedicinal inhalers which utilize electrical energy to vaporize or heat avolatile material, or attempt to provide the sensations of cigarette,cigar, or pipe smoking without burning tobacco to a significant degree.See, for example, the various alternative smoking articles, aerosoldelivery devices and heat generating sources set forth in the backgroundart described in U.S. Pat. No. 7,726,320 to Robinson et al.; and U.S.Pat. App. Pub. Nos. 2013/0255702 to Griffith, Jr. et al.; and2014/0096781 to Sears et al., which are incorporated herein byreference. See also, for example, the various types of smoking articles,aerosol delivery devices and electrically powered heat generatingsources referenced by brand name and commercial source in U.S. Pat. App.Pub. No. 2015/0220232 to Bless et al., which is incorporated herein byreference. Additional types of smoking articles, aerosol deliverydevices and electrically powered heat generating sources referenced bybrand name and commercial source are listed in U.S. Pat. App. Pub. No.2015/0245659 to DePiano et al., which is also incorporated herein byreference. Other representative cigarettes or smoking articles that havebeen described and, in some instances, been made commercially availableinclude those described in U.S. Pat. No. 4,735,217 to Gerth et al.; U.S.Pat. Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al.; U.S.Pat. No. 5,060,671 to Counts et al.; U.S. Pat. No. 5,249,586 to Morganet al.; U.S. Pat. No. 5,388,594 to Counts et al.; U.S. Pat. No.5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.;U.S. Pat. No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S.Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols;U.S. Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi;U.S. Pat. No. 7,726,320 to Robinson et al.; U.S. Pat. No. 7,896,006 toHamano; U.S. Pat. No. 6,772,756 to Shayan; U.S. Pat. Pub. No.2009/0095311 to Hon; U.S. Pat. Pub. Nos. 2006/0196518, 2009/0126745, and2009/0188490 to Hon; U.S. Pat. Pub. No. 2009/0272379 to Thorens et al.;U.S. Pat. Pub. Nos. 2009/0260641 and 2009/0260642 to Monsees et al.;U.S. Pat. Pub. Nos. 2008/0149118 and 2010/0024834 to Oglesby et al.;U.S. Pat. Pub. No. 2010/0307518 to Wang; and WO 2010/091593 to Hon,which are incorporated herein by reference.

Representative products that resemble many of the attributes oftraditional types of cigarettes, cigars or pipes have been marketed asACCORD® by Philip Morris Incorporated; ALPHA™, JOYE 510™ and M4™ byInnoVapor LLC; CIRRUS™ and FLING™ by White Cloud Cigarettes; BLU™ byFontem Ventures B.V; COHITA™ COLIBRI™, ELITE CLASSIC™, MAGNUM™, PHANTOM™and SENSE™ by EPUFFER® International Inc.; DUOPRO™, STORM™ andVAPORKING® by Electronic Cigarettes, Inc.; EGAR™ by Egar Australia;eGo-C™ and eGo-T™ by Joyetech; ELUSION™ by Elusion UK Ltd; EONSMOKE® byEonsmoke LLC; FIN™ by FIN Branding Group, LLC; SMOKE® by Green SmokeInc. USA; GREENARETTE™ by Greenarette LLC; HALLIGAN™, HENDU™, JET™MAXXQ™, PINK™ and PITBULL™ by SMOKE STIK®; HEATBAR™ by Philip MorrisInternational, Inc.; HYDRO IMPERIAL™ and LXE™ from Crown7; LOGIC™ andTHE CUBAN™ by LOGIC Technology; LUCI® by Luciano Smokes Inc.; METRO® byNicotek, LLC; NJOY® and ONEJOY™ by Sottera, Inc.; NO. 7™ by SS ChoiceLLC; PREMIUM ELECTRONIC CIGARETTE™ by PremiumEstore LLC; RAPP E-MYSTICK™by Ruyan America, Inc.; RED DRAGON™ by Red Dragon Products, LLC; RUYAN®by Ruyan Group (Holdings) Ltd.; SF® by Smoker Friendly International,LLC; GREEN SMART SMOKER® by The Smart Smoking Electronic CigaretteCompany Ltd.; SMOKE ASSIST® by Coastline Products LLC; SMOKINGEVERYWHERE® by Smoking Everywhere, Inc.; V2CIGS™ by VMR Products LLC;VAPOR NINE™ by VaporNine LLC; VAPOR4LIFE® by Vapor 4 Life, Inc.; VEPPO™by E-CigaretteDirect, LLC; VUSE® by R. J. Reynolds Vapor Company; MISTICMENTHOL product by Mistic Ecigs; the VYPE product by CN Creative Ltd;IQOS™ by Philip Morris International; GLO™ by British American Tobacco;MARK TEN products by Nu Mark LLC; and the JUUL product by Juul Labs,Inc. Yet other electrically powered aerosol delivery devices, and inparticular those devices that have been characterized as so-calledelectronic cigarettes, have been marketed under the tradenames COOLERVISIONS™; DIRECT E-CIG™; DRAGONFLY™; EMIST™; EVERSMOKE™; GAMUCCI®;HYBRID FLAME™; KNIGHT STICKS™; ROYAL BLUES™; SMOKETIP®; and SOUTH BEACHSMOKE™.

However, it may be desirable to provide aerosol delivery devices withimproved electronics such as may extend usability of the devices.

BRIEF SUMMARY

The present disclosure relates to powered (e.g., battery-powered)electronic devices, consumer electronics, and the like. In particular,some example implementations of the present disclosure relate to aerosoldelivery devices configured to produce aerosol and which aerosoldelivery devices, in some implementations, may be referred to aselectronic cigarettes, heat-not-burn cigarettes (or devices), orno-heat-no-burn devices. The present disclosure includes, withoutlimitation, the following example implementations.

Some example implementations provide an aerosol delivery devicecomprising a power source; an aerosol production component powerable toproduce an aerosol from an aerosol precursor composition; processingcircuitry configured to switchably connect the power source to a loadincluding the aerosol production component and thereby power the aerosolproduction component; and a piezo sensor operatively coupled with thepower source and the processing circuitry, the piezo sensor configuredto generate an electrical response to a deformation of the power source,the electrical response indicative of a characteristic of thedeformation, wherein the processing circuitry is configured to controlthe aerosol delivery device based at least in part on the characteristicof the deformation.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the characteristic of the deformation is anamount of the deformation, and the processing circuitry is furtherconfigured to measure the electrical response to determine the amount ofthe deformation and to control the aerosol delivery device to disable afunctionality of the aerosol delivery device when the amount of thedeformation is at least a threshold amount.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the processing circuitry is configured tocontrol the aerosol delivery device when the electrical responseindicates a fracture of or within the power source, or indicates atleast one of a threshold amount of mechanical stress, bending,shrinkage, or expansion on or of the power source.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the processing circuitry configured to controlthe aerosol delivery device includes the processing circuitry configuredto one or more of: lock the aerosol delivery device, disable charging ofthe power source, disable discharging of the power source, disconnectthe power source from the load, or provide user-perceptible feedbackregarding a state of the power source.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the piezo sensor includes a piezoelectricmaterial on a core material, the piezoelectric material configured togenerate an electrical voltage response to the deformation of the powersource.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the core material comprises a piezoresistivematerial configured to generate an electrical resistance response to thedeformation of the power source.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the piezo sensor includes a piezoresistivematerial on a core material, the piezoresistive material configured togenerate an electrical resistance response to the deformation of thepower source.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the core material comprises a piezoelectricmaterial configured to generate an electrical voltage response to thedeformation of the power source.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the power source comprises a battery includinga housing that contains an electrochemical cell, and that also containsthe piezo sensor that is configured to generate the electrical responseto a deformation of the electrochemical cell and thereby the powersource.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the piezo sensor is embedded within theelectrochemical cell.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the electrochemical cell and piezo sensor areformed in a multilayer arrangement including a cathode layer, an anodelayer, and a separator layer of the electrochemical cell, and includinga layer of composite material including at least one of piezoelectricmaterial or piezoresistive material for the piezo sensor.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the layer of composite material includes thepiezoelectric material on a core of piezoresistive material.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the layer of composite material includes thepiezoresistive material on a core of piezoelectric material.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the multilayer arrangement includes the layerof composite material deposited on a substrate, and the cathode layerdeposited on the layer of composite material so that the layer ofcomposite material is between the cathode layer and the substrate.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the multilayer arrangement includes the layerof composite material deposited on a substrate, and the anode layerdeposited on the layer of composite material so that the layer ofcomposite material is between the anode layer and the substrate.

Some example implementations provide a method of operating an aerosoldelivery device equipped with a power source, an aerosol productioncomponent, and a piezo sensor operatively coupled with the power source,the method comprising: switchably connecting the power source to a loadincluding the aerosol production component and thereby powering theaerosol production component to produce an aerosol from an aerosolprecursor composition; generating, by the piezo sensor, an electricalresponse to a deformation of the power source, the electrical responseindicative of a characteristic of the deformation; and controlling theaerosol delivery device based at least in part on the characteristic ofthe deformation indicated by the electrical response.

In some example implementations of the method of any preceding exampleimplementation, or any combination of any preceding exampleimplementations, the characteristic of the deformation is an amount ofthe deformation, the method further comprising: measuring the electricalresponse to determine the amount of the deformation, and the controllingthe aerosol delivery device further comprises disabling a functionalityof the aerosol delivery device when the amount of the deformation is atleast a threshold amount.

In some example implementations of the method of any preceding exampleimplementation, or any combination of any preceding exampleimplementations, controlling the aerosol delivery device furthercomprises controlling the aerosol delivery device when the electricalresponse indicates a fracture of or within the power source, orindicates at least one of a threshold amount of mechanical stress,bending, shrinkage, or expansion on or of the power source.

In some example implementations of the method of any preceding exampleimplementation, or any combination of any preceding exampleimplementations, controlling the aerosol delivery device furthercomprises one or more of locking the aerosol delivery device, disablingcharging of the power source, disabling discharging of the power source,disconnecting the power source from the load, or providinguser-perceptible feedback regarding a state of the power source.

Some example implementations provide a power source comprising: ahousing; and contained within the housing, an electrochemical cell; anda piezo sensor embedded within the electrochemical cell, the piezosensor configured to generate an electrical response to a deformation ofthe electrochemical cell and thereby the power source, the electricalresponse indicative of a characteristic of the deformation.

In some example implementations of the power source of any precedingexample implementation, or any combination of any preceding exampleimplementations, the piezo sensor includes a piezoelectric material on acore material, the piezoelectric material configured to generate anelectrical voltage response to the deformation of the power source.

In some example implementations of the power source of any precedingexample implementation, or any combination of any preceding exampleimplementations, the core material comprises a piezoresistive materialconfigured to generate an electrical resistance response to thedeformation of the power source.

In some example implementations of the power source of any precedingexample implementation, or any combination of any preceding exampleimplementations, the piezo sensor includes a piezoresistive material ona core material, the piezoresistive material configured to generate anelectrical resistance response to the deformation of the power source.

In some example implementations of the power source of any precedingexample implementation, or any combination of any preceding exampleimplementations, the core material comprises a piezoelectric materialconfigured to generate an electrical voltage response to the deformationof the power source.

In some example implementations of the power source of any precedingexample implementation, or any combination of any preceding exampleimplementations, the electrochemical cell and the piezo sensor areformed in a multilayer arrangement including a cathode layer, an anodelayer, and a separator layer of the electrochemical cell, and includinga layer of composite material including at least one of piezoelectricmaterial or piezoresistive material for the piezo sensor.

In some example implementations of the power source of any precedingexample implementation, or any combination of any preceding exampleimplementations, the layer of composite material includes thepiezoelectric material on a core of piezoresistive material.

In some example implementations of the power source of any precedingexample implementation, or any combination of any preceding exampleimplementations, the layer of composite material includes thepiezoresistive material on a core of piezoelectric material.

In some example implementations of the power source of any precedingexample implementation, or any combination of any preceding exampleimplementations, the multilayer arrangement includes the layer ofcomposite material deposited on a substrate, and the cathode layerdeposited on the layer of composite material so that the layer ofcomposite material is between the cathode layer and the substrate.

In some example implementations of the power source of any precedingexample implementation, or any combination of any preceding exampleimplementations, the multilayer arrangement includes the layer ofcomposite material deposited on a substrate, and the anode layerdeposited on the layer of composite material so that the layer ofcomposite material is between the anode layer and the substrate.

Some example implementations provide an electronic device comprising: apower source; processing circuitry configured to switchably connect thepower source to a load and thereby power the load to perform a functionof the electronic device; and a piezo sensor operatively coupled withthe power source and the processing circuitry, the piezo sensorconfigured to generate an electrical response to a deformation of thepower source, the electrical response indicative of a characteristic ofthe deformation, wherein the processing circuitry is configured tomeasure the electrical response and control the electronic device basedthereon.

In some example implementations of the electronic device of anypreceding example implementation, or any combination of any precedingexample implementations,

In some example implementations of the electronic device of anypreceding example implementation, or any combination of any precedingexample implementations, the processing circuitry is configured tocontrol the electronic device when the electrical response indicates afracture of or within the power source, or indicates at least one of athreshold amount of mechanical stress, bending, shrinkage, or expansionon or of the power source.

In some example implementations of the electronic device of anypreceding example implementation, or any combination of any precedingexample implementations, the processing circuitry configured to controlthe electronic device includes the processing circuitry configured toone or more of: lock the electronic device, disable charging of thepower source, disable discharging of the power source, disconnect thepower source from the load, or provide user-perceptible feedbackregarding a state of the power source.

In some example implementations of the electronic device of anypreceding example implementation, or any combination of any precedingexample implementations, the piezo sensor includes a piezoelectricmaterial on a core material, the piezoelectric material configured togenerate an electrical voltage response to the deformation of the powersource.

In some example implementations of the electronic device of anypreceding example implementation, or any combination of any precedingexample implementations, the core material comprises a piezoresistivematerial configured to generate an electrical resistance response to thedeformation of the power source.

In some example implementations of the electronic device of anypreceding example implementation, or any combination of any precedingexample implementations, the piezo sensor includes a piezoresistivematerial on a core material, the piezoresistive material configured togenerate an electrical resistance response to the deformation of thepower source.

In some example implementations of the electronic device of anypreceding example implementation, or any combination of any precedingexample implementations, the core material comprises a piezoelectricmaterial configured to generate an electrical voltage response to thedeformation of the power source.

In some example implementations of the electronic device of anypreceding example implementation, or any combination of any precedingexample implementations, the power source comprises a battery includinga housing that contains an electrochemical cell, and that also containsthe piezo sensor that is configured to generate the electrical responseto a deformation of the electrochemical cell and thereby the powersource.

In some example implementations of the electronic device of anypreceding example implementation, or any combination of any precedingexample implementations, the piezo sensor is embedded within theelectrochemical cell.

In some example implementations of the electronic device of anypreceding example implementation, or any combination of any precedingexample implementations, the electrochemical cell and piezo sensor areformed in a multilayer arrangement including a cathode layer, an anodelayer, and a separator layer of the electrochemical cell, and includinga layer of composite material including at least one of piezoelectricmaterial or piezoresistive material for the piezo sensor.

In some example implementations of the electronic device of anypreceding example implementation, or any combination of any precedingexample implementations, the layer of composite material includes thepiezoelectric material on a core of piezoresistive material.

In some example implementations of the electronic device of anypreceding example implementation, or any combination of any precedingexample implementations, the layer of composite material includes thepiezoresistive material on a core of piezoelectric material.

In some example implementations of the electronic device of anypreceding example implementation, or any combination of any precedingexample implementations, the multilayer arrangement includes the layerof composite material deposited on a substrate, and the cathode layerdeposited on the layer of composite material so that the layer ofcomposite material is between the cathode layer and the substrate.

In some example implementations of the electronic device of anypreceding example implementation, or any combination of any precedingexample implementations, the multilayer arrangement includes the layerof composite material deposited on a substrate, and the anode layerdeposited on the layer of composite material so that the layer ofcomposite material is between the anode layer and the substrate.

These and other features, aspects, and advantages of the presentdisclosure will be apparent from a reading of the following detaileddescription together with the accompanying figures, which are brieflydescribed below. The present disclosure includes any combination of two,three, four or more features or elements set forth in this disclosure,regardless of whether such features or elements are expressly combinedor otherwise recited in a specific example implementation describedherein. This disclosure is intended to be read holistically such thatany separable features or elements of the disclosure, in any of itsaspects and example implementations, should be viewed as combinable,unless the context of the disclosure clearly dictates otherwise.

It will therefore be appreciated that this Brief Summary is providedmerely for purposes of summarizing some example implementations so as toprovide a basic understanding of some aspects of the disclosure.Accordingly, it will be appreciated that the above described exampleimplementations are merely examples and should not be construed tonarrow the scope or spirit of the disclosure in any way. Other exampleimplementations, aspects and advantages will become apparent from thefollowing detailed description taken in conjunction with theaccompanying figures which illustrate, by way of example, the principlesof some described example implementations.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described aspects of the disclosure in the foregoing generalterms, reference will now be made to the accompanying figures, which arenot necessarily drawn to scale, and wherein:

FIG. 1 illustrates a perspective view of an aerosol delivery deviceincluding a cartridge and a control body that are coupled to oneanother, according to an example implementation of the presentdisclosure;

FIG. 2 is a partially cut-away view of the aerosol delivery device ofFIG. 1 in which the cartridge and control body are decoupled from oneanother, according to an example implementation;

FIGS. 3 and 4 illustrate a perspective view of an aerosol deliverydevice comprising a control body and an aerosol source member that arerespectively coupled to one another and decoupled from one another,according to another example implementation of the present disclosure;

FIGS. 5 and 6 illustrate respectively a front view of and a sectionalview through the aerosol delivery device of FIGS. 3 and 4 , according toan example implementation;

FIG. 7 illustrates a sectional view of an aerosol delivery deviceaccording to another example implementation;

FIGS. 8 and 9 illustrate respectively a side view and a partiallycut-away view of an aerosol delivery device including a cartridgecoupled to a control body, according to example implementations;

FIG. 10 illustrates a circuit diagram of an aerosol delivery deviceaccording to various example implementations of the present disclosure;

FIG. 11 is a flowchart illustrating various operations in a method ofoperation of an aerosol delivery device according to exampleimplementations;

FIGS. 12A, 12B, 13A, and 13B illustrate configurations of materials in apiezo sensor, according to example implementations;

FIG. 14 illustrates a partially cut-away view of a power source,according to example implementations; and

FIGS. 15A and 15B are flowcharts illustrating various operations in amethod of manufacturing a power source, according to exampleimplementations.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter withreference to example implementations thereof. These exampleimplementations are described so that this disclosure will be thoroughand complete, and will fully convey the scope of the disclosure to thoseskilled in the art. Indeed, the disclosure may be embodied in manydifferent forms and should not be construed as limited to theimplementations set forth herein; rather, these implementations areprovided so that this disclosure will satisfy applicable legalrequirements. As used in the specification and the appended claims, thesingular forms “a,” “an,” “the” and the like include plural referentsunless the context clearly dictates otherwise. Also, while reference maybe made herein to quantitative measures, values, geometric relationshipsor the like, unless otherwise stated, any one or more if not all ofthese may be absolute or approximate to account for acceptablevariations that may occur, such as those due to engineering tolerancesor the like.

As described hereinafter, example implementations of the presentdisclosure relate to aerosol delivery devices. Some aerosol deliverydevices according to the present disclosure use electrical energy toheat a material (preferably without combusting the material to anysignificant degree) to form an inhalable substance; and components ofsuch systems have the form of articles most preferably are sufficientlycompact to be considered hand-held devices. That is, use of componentsof preferred aerosol delivery devices does not result in the productionof smoke in the sense that aerosol results principally from by-productsof combustion or pyrolysis of tobacco, but rather, use of thosepreferred systems results in the production of vapors resulting fromvolatilization or vaporization of certain components incorporatedtherein. In some example implementations, components of aerosol deliverydevices may be characterized as electronic cigarettes, and thoseelectronic cigarettes most preferably incorporate tobacco and/orcomponents derived from tobacco, and hence deliver tobacco derivedcomponents in aerosol form.

Aerosol generating components of certain preferred aerosol deliverydevices may provide many of the sensations (e.g., inhalation andexhalation rituals, types of tastes or flavors, organoleptic effects,physical feel, use rituals, visual cues such as those provided byvisible aerosol, and the like) of smoking a cigarette, cigar or pipethat is employed by lighting and burning tobacco (and hence inhalingtobacco smoke), without any substantial degree of combustion of anycomponent thereof. For example, the user of an aerosol delivery devicein accordance with some example implementations of the presentdisclosure can hold and use that component much like a smoker employs atraditional type of smoking article, draw on one end of that componentfor inhalation of aerosol produced by that component, take or draw puffsat selected intervals of time, and the like.

While the systems are generally described herein in terms ofimplementations associated with aerosol delivery devices such asso-called “e-cigarettes,” “tobacco heating products” and the like, itshould be understood that the mechanisms, components, features, andmethods may be embodied in many different forms and associated with avariety of articles. For example, the description provided herein may beemployed in conjunction with implementations of traditional smokingarticles (e.g., cigarettes, cigars, pipes, etc.), heat-not-burncigarettes, and related packaging for any of the products disclosedherein. Accordingly, it should be understood that the description of themechanisms, components, features, and methods disclosed herein arediscussed in terms of implementations relating to aerosol deliverydevices by way of example only, and may be embodied and used in variousother products and methods.

Aerosol delivery devices of the present disclosure also can becharacterized as being vapor-producing articles or medicament deliveryarticles. Thus, such articles or devices can be adapted so as to provideone or more substances (e.g., flavors and/or pharmaceutical activeingredients) in an inhalable form or state. For example, inhalablesubstances can be substantially in the form of a vapor (i.e., asubstance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances can be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). For purposes of simplicity, the term “aerosol” asused herein is meant to include vapors, gases and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be smoke-like.

In use, aerosol delivery devices of the present disclosure may besubjected to many of the physical actions employed by an individual inusing a traditional type of smoking article (e.g., a cigarette, cigar orpipe that is employed by lighting and inhaling tobacco). For example,the user of an aerosol delivery device of the present disclosure canhold that article much like a traditional type of smoking article, drawon one end of that article for inhalation of aerosol produced by thatarticle, take puffs at selected intervals of time, etc.

Aerosol delivery devices of the present disclosure generally include anumber of components provided within an outer housing, which may bereferred to as a body or shell. The overall design of the housing canvary, and the format or configuration of the housing that can define theoverall size and shape of the aerosol delivery device can vary.Typically, an elongated body resembling the shape of a cigarette orcigar can be formed from a single, unitary housing or the elongatedhousing can be formed of two or more separable bodies. For example, anaerosol delivery device can comprise an elongated housing that can besubstantially tubular in shape and, as such, resemble the shape of aconventional cigarette or cigar. In one example, all of the componentsof the aerosol delivery device are contained within one housing.Alternatively, an aerosol delivery device can comprise two or morehousings that are joined and are separable. For example, an aerosoldelivery device can possess at one end a control body comprising ahousing containing one or more reusable components (e.g., an accumulatorsuch as a rechargeable battery, rechargeable supercapacitor, solid-statebattery (SSB), thin-film SSB, lithium-ion or hybrid lithium-ionsupercapacitor, and various electronics for controlling the operation ofthat article), and at the other end and removably coupleable thereto, anouter body or shell containing a disposable portion (e.g., a disposableflavor-containing cartridge). More specific formats, configurations andarrangements of components within the single housing type of unit orwithin a multi-piece separable housing type of unit will be evident inlight of the further disclosure provided herein. Additionally, variousaerosol delivery device designs and component arrangements can beappreciated upon consideration of the commercially available electronicaerosol delivery devices. It will be appreciated that alternativenon-tubular housing form factors can also be used, including, forexample, device housings having a shape and size generally approximatinga pack of cigarettes and form factors such as used on the GLO™ byBritish American Tobacco and IQOS™ by Philip Morris International, Inc.

As will be discussed in more detail below, aerosol delivery devices ofthe present disclosure comprise some combination of a power source(i.e., an electrical power source), at least one control component(e.g., means for actuating, controlling, regulating and ceasing powerfor heat generation, such as by controlling electrical current flow fromthe power source to other components of the aerosol delivery device), aheating element (e.g., an electrical resistance heating element or othercomponent and/or an inductive coil or other associated components and/orone or more radiant heating elements), and an aerosol precursorcomposition (e.g., a solid tobacco material, a semi-solid tobaccomaterial, or a liquid aerosol precursor composition) capable of yieldingan aerosol upon application of sufficient heat, and a mouth end regionor tip to allow drawing upon the aerosol delivery device for aerosolinhalation (e.g., a defined airflow path through the article such thataerosol generated can be withdrawn therefrom upon draw). In someimplementations, the power source includes a single battery or a singlebattery cell. The power source can power the heating element that isconfigured to convert electricity to heat and thereby vaporizecomponents of an aerosol precursor composition.

Alignment of the components within the aerosol delivery device of thepresent disclosure can vary. In specific implementations, the aerosolprecursor composition can be located near an end of the aerosol deliverydevice which may be configured to be positioned proximal to the mouth ofa user so as to maximize aerosol delivery to the user. Otherconfigurations, however, are not excluded. Generally, the heatingelement may be positioned sufficiently near the aerosol precursorcomposition so that heat from the heating element can volatilize theaerosol precursor (as well as one or more flavorants, medicaments, orthe like that may likewise be provided for delivery to a user) and forman aerosol for delivery to the user. When the heating element heats theaerosol precursor composition, an aerosol is formed, released, orgenerated in a physical form suitable for inhalation by a consumer. Itshould be noted that the foregoing terms are meant to be interchangeablesuch that reference to release, releasing, releases, or releasedincludes form or generate, forming or generating, forms or generates,and formed or generated. Specifically, an inhalable substance isreleased in the form of a vapor or aerosol or mixture thereof, whereinsuch terms are also interchangeably used herein except where otherwisespecified.

As noted above, the aerosol delivery device may incorporate a battery,supercapacitor, SSB or other power source to provide current flowsufficient to provide various functionalities to the aerosol deliverydevice, such as powering of a heating element, powering of controlsystems, powering of indicators, and the like. The power source can takeon various implementations. Preferably, the power source is able todeliver sufficient power to rapidly activate the heating element toprovide for aerosol formation and power the aerosol delivery devicethrough use for a desired duration of time. The power source preferablyis sized to fit conveniently within the aerosol delivery device so thatthe aerosol delivery device can be easily handled. Additionally, apreferred power source is of a sufficiently light weight to not detractfrom a desirable smoking experience.

More specific formats, configurations and arrangements of componentswithin the aerosol delivery device of the present disclosure will beevident in light of the further disclosure provided hereinafter. To theextent that any examples describe coating, growing, or depositing onematerial on another material, it is understood that various techniquesor alternatives may be utilized for connecting, joining, or adhering onematerial to another, including various types of material deposition,epitaxy, or the use of an adhesive. Additionally, the selection ofvarious aerosol delivery device components can be appreciated uponconsideration of the commercially available electronic aerosol deliverydevices. Further, the arrangement of the components within the aerosoldelivery device can also be appreciated upon consideration of thecommercially available electronic aerosol delivery devices.

As described hereinafter, some embodiments of the present disclosurerelate to aerosol delivery devices, though it will be appreciated thataspects of various embodiments may be applied mutatis mutandis toelectronic devices other than aerosol delivery devices. An electronicdevice may be a machine of any of a number of different types of machinethat includes a power source, processing circuitry configured toswitchably connect the power source to a load and thereby power the loadto perform a function of the machine. Examples of suitable types ofmachines include consumer electronics that are battery powered. Theseinclude computers such as portable computers (e.g., laptops, notebooks,tablet computers), mobile phones (e.g., cell phones, smartphones),wearable computers (e.g., smartwatches) or the like. Other examplesinclude remote-controlled cars, robots, video game consoles, and thelike.

Embodiments described with respect to application in aerosol deliverydevices are described by way of example and not by way of limitation.Aerosol delivery devices may be configured to heat an aerosol precursorcomposition (sometimes referred to as an inhalable substance medium) toproduce an aerosol (an inhalable substance). The aerosol precursorcomposition may comprise one or more of a solid tobacco material, asemi-solid tobacco material, or a liquid aerosol precursor composition.In some implementations, the aerosol delivery devices may be configuredto heat and produce an aerosol from a fluid aerosol precursorcomposition (e.g., a liquid aerosol precursor composition). Such aerosoldelivery devices may include so-called electronic cigarettes. In otherimplementations, the aerosol delivery devices may comprise heat-not-burndevices.

Liquid aerosol precursor composition, also referred to as a vaporprecursor composition or “e-liquid,” is particularly useful forelectronic cigarettes and no-heat-no-burn devices, as well as otherdevices that atomize or otherwise aerosolize a liquid to generate aninhalable aerosol. Liquid aerosol precursor composition may comprise avariety of components including, by way of example, a polyhydric alcohol(e.g., glycerin, propylene glycol, or a mixture thereof), nicotine,tobacco, tobacco extract, and/or flavorants. In some examples, theaerosol precursor composition comprises glycerin and nicotine.

Some liquid aerosol precursor compositions that may be used inconjunction with various implementations may include one or more acidssuch as levulinic acid, succinic acid, lactic acid, pyruvic acid,benzoic acid, fumaric acid, combinations thereof, and the like.Inclusion of an acid(s) in liquid aerosol precursor compositionsincluding nicotine may provide a protonated liquid aerosol precursorcomposition, including nicotine in salt form. Representative types ofliquid aerosol precursor components and formulations are set forth andcharacterized in U.S. Pat. No. 7,726,320 to Robinson et al., U.S. Pat.No. 9,254,002 to Chong et al., and U.S. Pat. App. Pub. Nos. 2013/0008457to Zheng et al., 2015/0020823 to Lipowicz et al., and 2015/0020830 toKoller, as well as PCT Pat. App. Pub. No. WO 2014/182736 to Bowen etal., and U.S. Pat. No. 8,881,737 to Collett et al., the disclosures ofwhich are incorporated herein by reference. Other aerosol precursorsthat may be employed include the aerosol precursors that have beenincorporated in any of a number of the representative productsidentified above. Also desirable are the so-called “smoke juices” forelectronic cigarettes that have been available from Johnson CreekEnterprises LLC. Still further example aerosol precursor compositionsare sold under the brand names BLACK NOTE, COSMIC FOG, THE MILKMANE-LIQUID, FIVE PAWNS, THE VAPOR CHEF, VAPE WILD, BOOSTED, THE STEAMFACTORY, MECH SAUCE, CASEY JONES MAINLINE RESERVE, MITTEN VAPORS, DR.CRIMMY'S V-LIQUID, SMILEY E LIQUID, BEANTOWN VAPOR, CUTTWOOD, CYCLOPSVAPOR, SICBOY, GOOD LIFE VAPOR, TELEOS, PINUP VAPORS, SPACE JAM, MT.BAKER VAPOR, and JIMMY THE JUICE MAN. Implementations of effervescentmaterials can be used with the aerosol precursor, and are described, byway of example, in U.S. Pat. App. Pub. No. 2012/0055494 to Hunt et al.,which is incorporated herein by reference. Further, the use ofeffervescent materials is described, for example, in U.S. Pat. No.4,639,368 to Niazi et al., U.S. Pat. No. 5,178,878 to Wehling et al.,U.S. Pat. No. 5,223,264 to Wehling et al., U.S. Pat. No. 6,974,590 toPather et al., U.S. Pat. No. 7,381,667 to Bergquist et al., U.S. Pat.No. 8,424,541 to Crawford et al, U.S. Pat. No. 8,627,828 to Stricklandet al., and U.S. Pat. No. 9,307,787 to Sun et al., as well as U.S. Pat.App. Pub. Nos. 2010/0018539 to Brinkley et al., and PCT Pat. App. Pub.No. WO 97/06786 to Johnson et al., all of which are incorporated byreference herein.

The aerosol precursor composition may additionally or alternativelyinclude other active ingredients including, but not limited to,botanical ingredients (e.g., lavender, peppermint, chamomile, basil,rosemary, thyme, eucalyptus, ginger, cannabis, ginseng, maca, andtisanes), stimulants (e.g., caffeine and guarana), amino acids (e.g.,taurine, theanine, phenylalanine, tyrosine, and tryptophan) and/orpharmaceutical, nutraceutical, and medicinal ingredients (e.g.,vitamins, such as B6, B12, and C and cannabinoids, such astetrahydrocannabinol (THC) and cannabidiol (CBD).

Representative types of substrates, reservoirs or other components forsupporting the aerosol precursor are described in U.S. Pat. No.8,528,569 to Newton, U.S. Pat. App. Pub. No. 2014/0261487 to Chapman etal., U.S. Pat. App. Pub. No. 2015/0059780 to Davis et al., and U.S. Pat.App. Pub. No. 2015/0216232 to Bless et al., all of which areincorporated herein by reference. Additionally, various wickingmaterials, and the configuration and operation of those wickingmaterials within certain types of electronic cigarettes, are set forthin U.S. Pat. No. 8,910,640 to Sears et al., which is incorporated hereinby reference.

In other implementations, the aerosol delivery devices may compriseheat-not-burn devices, configured to heat a solid aerosol precursorcomposition (e.g., an extruded tobacco rod) or a semi-solid aerosolprecursor composition (e.g., a glycerin-loaded tobacco paste). Theaerosol precursor composition may comprise tobacco-containing beads,tobacco shreds, tobacco strips, reconstituted tobacco material, orcombinations thereof, and/or a mix of finely ground tobacco, tobaccoextract, spray dried tobacco extract, or other tobacco form mixed withoptional inorganic materials (such as calcium carbonate), optionalflavors, and aerosol forming materials to form a substantially solid ormoldable (e.g., extrudable) substrate. Representative types of solid andsemi-solid aerosol precursor compositions and formulations are disclosedin U.S. Pat. No. 8,424,538 to Thomas et al., U.S. Pat. No. 8,464,726 toSebastian et al., U.S. Pat. App. Pub. No. 2015/0083150 to Conner et al.,U.S. Pat. App. Pub. No. 2015/0157052 to Ademe et al., and U.S. Pat. App.Pub. No. 2017/0000188 to Nordskog et al., all of which are incorporatedby reference herein. Further representative types of solid andsemi-solid aerosol precursor compositions and arrangements include thosefound in the NEOSTIKS™ consumable aerosol source members for the GLO™product by British American Tobacco and in the HEETS™ consumable aerosolsource members for the IQOS™ product by Philip Morris International,Inc.

In various implementations, the inhalable substance specifically may bea tobacco component or a tobacco-derived material (i.e., a material thatis found naturally in tobacco that may be isolated directly from thetobacco or synthetically prepared). For example, the aerosol precursorcomposition may comprise tobacco extracts or fractions thereof combinedwith an inert substrate. The aerosol precursor composition may furthercomprise unburned tobacco or a composition containing unburned tobaccothat, when heated to a temperature below its combustion temperature,releases an inhalable substance. In some implementations, the aerosolprecursor composition may comprise tobacco condensates or fractionsthereof (i.e., condensed components of the smoke produced by thecombustion of tobacco, leaving flavors and, possibly, nicotine).

Tobacco materials useful in the present disclosure can vary and mayinclude, for example, flue-cured tobacco, burley tobacco, Orientaltobacco or Maryland tobacco, dark tobacco, dark-fired tobacco andRustica tobaccos, as well as other rare or specialty tobaccos, or blendsthereof. Tobacco materials also can include so-called “blended” formsand processed forms, such as processed tobacco stems (e.g., cut-rolledor cut-puffed stems), volume expanded tobacco (e.g., puffed tobacco,such as dry ice expanded tobacco (DIET), preferably in cut filler form),reconstituted tobaccos (e.g., reconstituted tobaccos manufactured usingpaper-making type or cast sheet type processes). Various representativetobacco types, processed types of tobaccos, and types of tobacco blendsare set forth in U.S. Pat. No. 4,836,224 to Lawson et al., U.S. Pat. No.4,924,888 to Perfetti et al., U.S. Pat. No. 5,056,537 to Brown et al.,U.S. Pat. No. 5,159,942 to Brinkley et al., U.S. Pat. No. 5,220,930 toGentry, U.S. Pat. No. 5,360,023 to Blakley et al., U.S. Pat. No.6,701,936 to Shafer et al., U.S. Pat. No. 7,011,096 to Li et al., andU.S. Pat. No. 7,017,585 to Li et al., U.S. Pat. No. 7,025,066 to Lawsonet al., U.S. Pat. App. Pub. No. 2004/0255965 to Perfetti et al., PCTPat. App. Pub. No. WO 02/37990 to Bereman, and Bombick et al., Fund.Appl. Toxicol., 39, p. 11-17 (1997), which are incorporated herein byreference. Further example tobacco compositions that may be useful in asmoking device, including according to the present disclosure, aredisclosed in U.S. Pat. No. 7,726,320 to Robinson et al., which isincorporated herein by reference.

Still further, the aerosol precursor composition may comprise an inertsubstrate having the inhalable substance, or a precursor thereof,integrated therein or otherwise deposited thereon. For example, a liquidcomprising the inhalable substance may be coated on or absorbed oradsorbed into the inert substrate such that, upon application of heat,the inhalable substance is released in a form that can be withdrawn fromthe inventive article through application of positive or negativepressure. In some aspects, the aerosol precursor composition maycomprise a blend of flavorful and aromatic tobaccos in cut filler form.In another aspect, the aerosol precursor composition may comprise areconstituted tobacco material, such as described in U.S. Pat. No.4,807,809 to Pryor et al., U.S. Pat. No. 4,889,143 to Pryor et al. andU.S. Pat. No. 5,025,814 to Raker, the disclosures of which areincorporated herein by reference. For further information regardingsuitable aerosol precursor composition, see U.S. patent application Ser.No. 15/916,834 to Sur et al., filed Mar. 9, 2018, which is incorporatedherein by reference.

Regardless of the type of aerosol precursor composition heated, aerosoldelivery devices may include a heating element configured to heat theaerosol precursor composition. In some implementations, the heatingelement is an induction heater. Such heaters often comprise an inductiontransmitter and an induction receiver. The induction transmitter mayinclude a coil configured to create an oscillating magnetic field (e.g.,a magnetic field that varies periodically with time) when alternatingcurrent is directed through it. The induction receiver may be at leastpartially located or received within the induction transmitter and mayinclude a conductive material (e.g., ferromagnetic material or analuminum coated material). By directing alternating current through theinduction transmitter, eddy currents may be generated in the inductionreceiver via induction. The eddy currents flowing through the resistanceof the material defining the induction receiver may heat it by Jouleheating (i.e., through the Joule effect). The induction receiver, whichmay define an atomizer, may be wirelessly heated to form an aerosol froman aerosol precursor composition positioned in proximity to theinduction receiver. Various implementations of an aerosol deliverydevice with an induction heater are described in U.S. Pat. App. Pub. No.2017/0127722 to Davis et al., U.S. Pat. App. Pub. No. 2017/0202266 toSur et al., U.S. patent application Ser. No. 15/352,153 to Sur et al.,filed Nov. 15, 2016, U.S. patent application Ser. No. 15/799,365 toSebastian et al., filed Oct. 31, 2017, and U.S. patent application Ser.No. 15/836,086 to Sur, all of which are incorporated by referenceherein.

In other implementations including those described more particularlyherein, the heating element is a conductive heater such as in the caseof electrical resistance heater. These heaters may be configured toproduce heat when an electrical current is directed through it. Invarious implementations, a conductive heater may be provided in avariety forms, such as in the form of a foil, a foam, a plate, discs,spirals, fibers, wires, films, yarns, strips, ribbons or cylinders. Suchheaters often include a metal material and are configured to produceheat as a result of the electrical resistance associated with passing anelectrical current through it. Such resistive heaters may be positionedin proximity to and heat an aerosol precursor composition to produce anaerosol. A variety of conductive substrates that may be usable with thepresent disclosure are described in the above-cited U.S. Pat. App. Pub.No. 2013/0255702 to Griffith et al. Other examples of suitable heatersare described in U.S. Pat. No. 9,491,974 to DePiano et al., which isincorporated by reference herein.

In some implementations aerosol delivery devices may include a controlbody and a cartridge in the case of so-called electronic cigarettes, ora control body and an aerosol source member in the case of heat-not-burndevices. In the case of either electronic cigarettes or heat-not-burndevices, the control body may be reusable, whereas the cartridge/aerosolsource member may be configured for a limited number of uses and/orconfigured to be disposable. The cartridge/aerosol source member mayinclude the aerosol precursor composition. In order to heat the aerosolprecursor composition, the heating element may be positioned in contactwith or proximate the aerosol precursor composition, such as across thecontrol body and cartridge, or in the control body in which the aerosolsource member may be positioned. The control body may include a powersource, which may be rechargeable or replaceable, and thereby thecontrol body may be reused with multiple cartridges/aerosol sourcemembers.

The control body may also include means to activate the aerosol deliverydevice such as a pushbutton, touch-sensitive surface or the like formanual control of the device. Additionally or alternatively, the controlbody may include a flow sensor to detect when a user draws on thecartridge/aerosol source member to thereby activate the aerosol deliverydevice.

In various implementations, the aerosol delivery device according to thepresent disclosure may have a variety of overall shapes, including, butnot limited to an overall shape that may be defined as beingsubstantially rod-like, rod-shaped or substantially tubular shaped orsubstantially cylindrically shaped. In the implementations shown in anddescribed with reference to the accompanying figures, the aerosoldelivery device has a substantially round cross-section; however, othercross-sectional shapes (e.g., oval, square, rectangle, triangle, etc.)also are encompassed by the present disclosure. Such language that isdescriptive of the physical shape of the article may also be applied tothe individual components thereof, including the control body and thecartridge/aerosol source member. In other implementations, the controlbody may take another handheld shape, such as a small box shape.

In more specific implementations, one or both of the control body andthe cartridge/aerosol source member may be referred to as beingdisposable or as being reusable. For example, the control body may havea power source such as a replaceable battery or a rechargeable battery,SSB, thin-film SSB, rechargeable supercapacitor, lithium-ion or hybridlithium-ion supercapacitor, or the like. One example of a power sourceis a TKI-1550 rechargeable lithium-ion battery produced by TadiranBatteries GmbH of Germany. In another implementation, a useful powersource may be a N50-AAA CADNICA nickel-cadmium cell produced by SanyoElectric Company, Ltd., of Japan. In other implementations, a pluralityof such batteries, for example providing 1.2-volts each, may beconnected in series.

In some examples, then, the power source may be connected to and therebycombined with any type of recharging technology. Examples of suitablechargers include chargers that simply supply constant or pulsed directcurrent (DC) power to the power source, fast chargers that add controlcircuitry, three-stage chargers, induction-powered chargers, smartchargers, motion-powered chargers, pulsed chargers, solar chargers,USB-based chargers and the like. In some examples, the charger includesa power adapter and any suitable charge circuitry. In other examples,the charger includes the power adapter and the control body is equippedwith charge circuitry. In these other examples, the charger may at timesbe simply referred to as a power adapter.

The control body may include any of a number of different terminals,electrical connectors or the like to connect to a suitable charger, andin some examples, to connect to other peripherals for communication.More specific suitable examples include direct current (DC) connectorssuch as cylindrical connectors, cigarette lighter connectors and USBconnectors including those specified by USB 1.x (e.g., Type A, Type B),USB 2.0 and its updates and additions (e.g., Mini A, Mini B, Mini AB,Micro A, Micro B, Micro AB) and USB 3.x (e.g., Type A, Type B, Micro B,Micro AB, Type C), proprietary connectors such as Apple's Lightningconnector, and the like. The control body may directly connect with thecharger or other peripheral, or the two may connect via an appropriatecable that also has suitable connectors. In examples in which the twoare connected by cable, the control body and charger or other peripheralmay have the same or different type of connector with the cable havingthe one type of connector or both types of connectors.

In examples involving induction-powered charging, the aerosol deliverydevice may be equipped with inductive wireless charging technology andinclude an induction receiver to connect with a wireless charger,charging pad or the like that includes an induction transmitter and usesinductive wireless charging (including for example, wireless chargingaccording to the Qi wireless charging standard from the Wireless PowerConsortium (WPC)). Or the power source may be recharged from a wirelessradio frequency (RF) based charger. An example of an inductive wirelesscharging system is described in U.S. Pat. App. Pub. No. 2017/0112196 toSur et al., which is incorporated herein by reference in its entirety.Further, in some implementations in the case of an electronic cigarette,the cartridge may comprise a single-use cartridge, as disclosed in U.S.Pat. No. 8,910,639 to Chang et al., which is incorporated herein byreference.

One or more connections may be employed to connect the power source to arecharging technology, and some may involve a charging case, cradle,dock, sleeve or the like. More specifically, for example, the controlbody may be configured to engage a cradle that includes a USB connectorto connect to a power supply. Or in another example, the control bodymay be configured to fit within and engage a sleeve that includes a USBconnector to connect to a power supply. In these and similar examples,the USB connector may connect directly to the power source, or the USBconnector may connect to the power source via a suitable power adapter.

Examples of power sources are described in U.S. Pat. No. 9,484,155 toPeckerar et al., and U.S. Pat. App. Pub. No. 2017/0112191 to Sur et al.,filed Oct. 21, 2015, the disclosures of which are incorporated herein byreference. With respect to the flow sensor, representative currentregulating components and other current controlling components includingvarious microcontrollers, sensors, and switches for aerosol deliverydevices are described in U.S. Pat. No. 4,735,217 to Gerth et al., U.S.Pat. Nos. 4,922,901, 4,947,874, and 4,947,875, all to Brooks et al.,U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 toFleischhauer et al., U.S. Pat. No. 7,040,314 to Nguyen et al., U.S. Pat.No. 8,205,622 to Pan, U.S. Pat. No. 8,881,737 to Collet et al., U.S.Pat. No. 9,423,152 to Ampolini et al., U.S. Pat. No. 9,439,454 toFernando et al., and U.S. Pat. App. Pub. No. 2015/0257445 to Henry etal., all of which are incorporated herein by reference.

An input element may be included with the aerosol delivery device (andmay replace or supplement a flow sensor). The input may be included toallow a user to control functions of the device and/or for output ofinformation to a user. Any component or combination of components may beutilized as an input for controlling the function of the device. Forexample, one or more pushbuttons may be used as described in U.S. Pub.No. 2015/0245658 to Worm et al., which is incorporated herein byreference. Likewise, a touchscreen may be used as described in U.S.patent application Ser. No. 14/643,626, filed Mar. 10, 2015, to Sears etal., which is incorporated herein by reference. As a further example,components adapted for gesture recognition based on specified movementsof the aerosol delivery device may be used as an input. See U.S. Pub.2016/0158782 to Henry et al., which is incorporated herein by reference.As still a further example, a capacitive sensor may be implemented onthe aerosol delivery device to enable a user to provide input, such asby touching a surface of the device on which the capacitive sensor isimplemented. In another example, a sensor capable of detecting a motionassociated with the device (e.g., accelerometer, gyroscope,photoelectric proximity sensor, etc.) may be implemented on the aerosoldelivery device to enable a user to provide input. Examples of suitablesensors are described in U.S. Pat. App. Pub. No. 2018/0132528 to Sur etal., and U.S. Pat. App. Pub. No. 2016/0158782 to Henry et al., which areincorporated herein by reference.

As indicated above, the aerosol delivery device may include variouselectronics such as at least one control component. A suitable controlcomponent may include a number of electronic components, and in someexamples may be formed of a circuit board such as a printed circuitboard (PCB). In some examples, the electronic components includeprocessing circuitry configured to perform data processing, applicationexecution, or other processing, control or management services accordingto one or more example implementations. The processing circuitry mayinclude a processor embodied in a variety of forms such as at least oneprocessor core, microprocessor, coprocessor, controller, microcontrolleror various other computing or processing devices including one or moreintegrated circuits such as, for example, an ASIC (application specificintegrated circuit), an FPGA (field programmable gate array), somecombination thereof, or the like. In some examples, the processingcircuitry may include memory coupled to or integrated with theprocessor, and which may store data, computer program instructionsexecutable by the processor, some combination thereof, or the like.

In some examples, the control component may include one or moreinput/output peripherals, which may be coupled to or integrated with theprocessing circuitry. More particularly, the control component mayinclude a communication interface to enable wireless communication withone or more networks, computing devices or other appropriately-enableddevices. Examples of suitable communication interfaces are disclosed inU.S. Pat. App. Pub. No. 2016/0261020 to Marion et al., the content ofwhich is incorporated herein by reference. Another example of a suitablecommunication interface is the CC3200 single chip wirelessmicrocontroller unit (MCU) from Texas Instruments. And examples ofsuitable manners according to which the aerosol delivery device may beconfigured to wirelessly communicate are disclosed in U.S. Pat. App.Pub. No. 2016/0007651 to Ampolini et al., and U.S. Pat. App. Pub. No.2016/0219933 to Henry, Jr. et al., each of which is incorporated hereinby reference.

Still further components can be utilized in the aerosol delivery deviceof the present disclosure. One example of a suitable component is anindicator such as light-emitting diodes (LEDs), quantum dot-based LEDsor the like, which may be illuminated with use of the aerosol deliverydevice. Examples of suitable LED components, and the configurations anduses thereof, are described in U.S. Pat. No. 5,154,192 to Sprinkel etal., U.S. Pat. No. 8,499,766 to Newton, U.S. Pat. No. 8,539,959 toScatterday, and U.S. Pat. No. 9,451,791 to Sears et al., all of whichare incorporated herein by reference.

Other indices of operation are also encompassed by the presentdisclosure. For example, visual indicators of operation also includechanges in light color or intensity to show progression of the smokingexperience. Tactile (haptic) indicators of operation and sound (audio)indicators of operation similarly are encompassed by the disclosure.Moreover, combinations of such indicators of operation also are suitableto be used in a single smoking article. According to another aspect, theaerosol delivery device may include one or more indicators or indicia,such as, for example, a display configured to provide informationcorresponding to the operation of the smoking article such as, forexample, the amount of power remaining in the power source, progressionof the smoking experience, indication corresponding to activating a heatsource, and/or the like.

Yet other components are also contemplated. For example, U.S. Pat. No.5,154,192 to Sprinkel et al. discloses indicators for smoking articles;U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses piezoelectric sensorsthat can be associated with the mouth-end of a device to detect user lipactivity associated with taking a draw and then trigger heating of aheating device; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses apuff sensor for controlling energy flow into a heating load array inresponse to pressure drop through a mouthpiece; U.S. Pat. No. 5,967,148to Harris et al. discloses receptacles in a smoking device that includean identifier that detects a non-uniformity in infrared transmissivityof an inserted component and a controller that executes a detectionroutine as the component is inserted into the receptacle; U.S. Pat. No.6,040,560 to Fleischhauer et al. describes a defined executable powercycle with multiple differential phases; U.S. Pat. No. 5,934,289 toWatkins et al. discloses photonic-optronic components; U.S. Pat. No.5,954,979 to Counts et al. discloses means for altering draw resistancethrough a smoking device; U.S. Pat. No. 6,803,545 to Blake et al.discloses specific battery configurations for use in smoking devices;U.S. Pat. No. 7,293,565 to Griffen et al. discloses various chargingsystems for use with smoking devices; U.S. Pat. No. 8,402,976 toFernando et al. discloses computer interfacing means for smoking devicesto facilitate charging and allow computer control of the device; U.S.Pat. No. 8,689,804 to Fernando et al. discloses identification systemsfor smoking devices; and PCT Pat. App. Pub. No. WO 2010/003480 by Flickdiscloses a fluid flow sensing system indicative of a puff in an aerosolgenerating system; all of the foregoing disclosures being incorporatedherein by reference.

Further examples of components related to electronic aerosol deliveryarticles and disclosing materials or components that may be used in thepresent article include U.S. Pat. No. 4,735,217 to Gerth et al., U.S.Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,666,977 to Higginset al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 toFelter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No.7,832,410 to Hon, U.S. Pat. No. 7,513,253 to Kobayashi, U.S. Pat. No.7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. Nos.8,156,944 and 8,375,957 to Hon, U.S. Pat. No. 8,794,231 to Thorens etal., U.S. Pat. No. 8,851,083 to Oglesby et al., U.S. Pat. Nos. 8,915,254and 8,925,555 to Monsees et al., U.S. Pat. No. 9,220,302 to DePiano etal., U.S. Pat. App. Pub. Nos. 2006/0196518 and 2009/0188490 to Hon, U.S.Pat. App. Pub. No. 2010/0024834 to Oglesby et al., U.S. Pat. App. Pub.No. 2010/0307518 to Wang, PCT Pat. App. Pub. No. WO 2010/091593 to Hon,and PCT Pat. App. Pub. No. WO 2013/089551 to Foo, each of which isincorporated herein by reference. Further, U.S. Pat. App. Pub. No.2017/0099877 to Worm et al., discloses capsules that may be included inaerosol delivery devices and fob-shape configurations for aerosoldelivery devices, and is incorporated herein by reference. A variety ofthe materials disclosed by the foregoing documents may be incorporatedinto the present devices in various implementations, and all of theforegoing disclosures are incorporated herein by reference.

Yet other features, controls or components that can be incorporated intoaerosol delivery devices of the present disclosure are described in U.S.Pat. No. 5,967,148 to Harris et al., U.S. Pat. No. 5,934,289 to Watkinset al., U.S. Pat. No. 5,954,979 to Counts et al., U.S. Pat. No.6,040,560 to Fleischhauer et al., U.S. Pat. No. 8,365,742 to Hon, U.S.Pat. No. 8,402,976 to Fernando et al., U.S. Pat. App. Pub. No.2005/0016550 to Katase, U.S. Pat. No. 8,689,804 to Fernando et al., U.S.Pat. App. Pub. No. 2013/0192623 to Tucker et al., U.S. Pat. No.9,427,022 to Leven et al., U.S. Pat. App. Pub. No. 2013/0180553 to Kimet al., U.S. Pat. App. Pub. No. 2014/0000638 to Sebastian et al., U.S.Pat. App. Pub. No. 2014/0261495 to Novak et al., and U.S. Pat. No.9,220,302 to DePiano et al., all of which are incorporated herein byreference.

FIGS. 1 and 2 illustrate implementations of an aerosol delivery deviceincluding a control body and a cartridge in the case of an electroniccigarette. More specifically, FIGS. 1 and 2 illustrate an aerosoldelivery device 100 according to an example implementation of thepresent disclosure. As indicated, the aerosol delivery device mayinclude a control body 102 and a cartridge 104. The control body and thecartridge can be permanently or detachably aligned in a functioningrelationship. In this regard, FIG. 1 illustrates a perspective view ofthe aerosol delivery device in a coupled configuration, whereas FIG. 2illustrates a partially cut-away side view of the aerosol deliverydevice in a decoupled configuration. The aerosol delivery device may,for example, be substantially rod-like or rod-shaped, substantiallytubular shaped, or substantially cylindrically shaped in someimplementations when the control body and the cartridge are in anassembled configuration.

The control body 102 and the cartridge 104 can be configured to engageone another by a variety of connections, such as a press fit (orinterference fit) connection, a threaded connection, a magneticconnection, or the like. As such, the control body may include a firstengaging element (e.g., a coupler) that is adapted to engage a secondengaging element (e.g., a connector) on the cartridge. The firstengaging element and the second engaging element may be reversible. Asan example, either of the first engaging element or the second engagingelement may be a male thread, and the other may be a female thread. As afurther example, either the first engaging element or the secondengaging element may be a magnet, and the other may be a metal or amatching magnet. In particular implementations, engaging elements may bedefined directly by existing components of the control body and thecartridge. For example, the housing of the control body may define acavity at an end thereof that is configured to receive at least aportion of the cartridge (e.g., a storage tank or other shell-formingelement of the cartridge). In particular, a storage tank of thecartridge may be at least partially received within the cavity of thecontrol body while a mouthpiece of the cartridge remains exposed outsideof the cavity of the control body. The cartridge may be retained withinthe cavity formed by the control body housing, such as by aninterference fit (e.g., through use of detents and/or other featurescreating an interference engagement between an outer surface of thecartridge and an interior surface of a wall forming the control bodycavity), by a magnetic engagement (e.g., though use of magnets and/ormagnetic metals positioned within the cavity of the control body andpositioned on the cartridge), or by other suitable techniques.

As seen in the cut-away view illustrated in FIG. 2 , the control body102 and cartridge 104 each include a number of respective components.The components illustrated in FIG. 2 are representative of thecomponents that may be present in a control body and cartridge and arenot intended to limit the scope of components that are encompassed bythe present disclosure. As shown, for example, the control body can beformed of a housing 206 (sometimes referred to as a control body shell)that can include a control component 208 (e.g., processing circuitry,etc.), a flow sensor 210, a power source 212 (e.g., battery,supercapacitor), and an indicator 214 (e.g., LED, quantum dot-basedLED), and such components can be variably aligned.

The cartridge 104 can be formed of a housing 216 (sometimes referred toas the cartridge shell) enclosing a reservoir 218 configured to retainthe aerosol precursor composition, and including a heating element 220(sometimes referred to as a heater). In various configurations, thisstructure may be referred to as a tank; and accordingly, the terms“cartridge,” “tank” and the like may be used interchangeably to refer toa shell or other housing enclosing a reservoir for aerosol precursorcomposition, and including a heating element.

As shown, in some examples, the reservoir 218 may be in fluidcommunication with a liquid transport element 222 adapted to wick orotherwise transport an aerosol precursor composition stored in thereservoir housing to the heating element 220. Other arrangements ofliquid transport elements are contemplated within the scope of thedisclosure. For example, in some embodiments, a liquid transport elementmay be positioned proximate a distal end of the reservoir and arrangedtransverse to a longitudinal axis of the reservoir. In some examples, avalve may be positioned between the reservoir and heating element, andconfigured to control an amount of aerosol precursor composition passedor delivered from the reservoir to the heating element.

Various examples of materials configured to produce heat when electricalcurrent is applied therethrough may be employed to form the heatingelement 220. The heating element in these examples may be a resistiveheating element such as a wire coil, flat plate, micro heater or thelike. Example materials from which the heating element may be formedinclude Kanthal (FeCrAl), nichrome, nickel, stainless steel, indium tinoxide, tungsten, molybdenum disilicide (MoSi₂), molybdenum silicide(MoSi), molybdenum disilicide doped with aluminum (Mo(Si,Al)₂),titanium, platinum, silver, palladium, alloys of silver and palladium,graphite and graphite-based materials (e.g., carbon-based foams andyarns), conductive inks, boron doped silica, and ceramics (e.g.,positive or negative temperature coefficient ceramics). The heatingelement may be resistive heating element or a heating element configuredto generate heat through induction. The heating element may be coated byheat conductive ceramics such as aluminum nitride, silicon carbide,beryllium oxide, alumina, silicon nitride, or their composites. Exampleimplementations of heating elements useful in aerosol delivery devicesaccording to the present disclosure are further described below, and canbe incorporated into devices such as those described herein.

An opening 224 may be present in the housing 216 (e.g., at the mouthend) to allow for egress of formed aerosol from the cartridge 104.

The cartridge 104 also may include one or more electronic components226, which may include an integrated circuit, a memory component (e.g.,EEPROM, flash memory), a sensor, or the like. The electronic componentsmay be adapted to communicate with the control component 208 and/or withan external device by wired or wireless means. The electronic componentsmay be positioned anywhere within the cartridge or a base 228 thereof.

Although the control component 208 and the flow sensor 210 areillustrated separately, it is understood that various electroniccomponents including the control component and the flow sensor may becombined on a circuit board (e.g., PCB) that supports and electricallyconnects the electronic components. Further, the circuit board may bepositioned horizontally relative the illustration of FIG. 1 in that thecircuit board can be lengthwise parallel to the central axis of thecontrol body. In some examples, the air flow sensor may comprise its owncircuit board or other base element to which it can be attached. In someexamples, a flexible circuit board may be utilized. A flexible circuitboard may be configured into a variety of shapes, include substantiallytubular shapes. In some examples, a flexible circuit board may becombined with, layered onto, or form part or all of a heater substrate.

The control body 102 and the cartridge 104 may include componentsadapted to facilitate a fluid engagement therebetween. As illustrated inFIG. 2 , the control body can include a coupler 230 having a cavity 232therein. The base 228 of the cartridge can be adapted to engage thecoupler and can include a projection 234 adapted to fit within thecavity. Such engagement can facilitate a stable connection between thecontrol body and the cartridge as well as establish an electricalconnection between the power source 212 and control component 208 in thecontrol body and the heating element 220 in the cartridge. Further, thehousing 206 can include an air intake 236, which may be a notch in thehousing where it connects to the coupler that allows for passage ofambient air around the coupler and into the housing where it then passesthrough the cavity 232 of the coupler and into the cartridge through theprojection 234.

A coupler and a base useful according to the present disclosure aredescribed in U.S. Pat. App. Pub. No. 2014/0261495 to Novak et al., whichis incorporated herein by reference. For example, the coupler 230 asseen in FIG. 2 may define an outer periphery 238 configured to mate withan inner periphery 240 of the base 228. In one example the innerperiphery of the base may define a radius that is substantially equalto, or slightly greater than, a radius of the outer periphery of thecoupler. Further, the coupler may define one or more protrusions 242 atthe outer periphery configured to engage one or more recesses 244defined at the inner periphery of the base. However, various otherexamples of structures, shapes and components may be employed to couplethe base to the coupler. In some examples the connection between thebase of the cartridge 104 and the coupler of the control body 102 may besubstantially permanent, whereas in other examples the connectiontherebetween may be releasable such that, for example, the control bodymay be reused with one or more additional cartridges that may bedisposable and/or refillable.

The reservoir 218 illustrated in FIG. 2 can be a container or can be afibrous reservoir, as presently described. For example, the reservoircan comprise one or more layers of nonwoven fibers substantially formedinto the shape of a tube encircling the interior of the housing 216, inthis example. An aerosol precursor composition can be retained in thereservoir. Liquid components, for example, can be sorptively retained bythe reservoir. The reservoir can be in fluid connection with the liquidtransport element 222. The liquid transport element can transport theaerosol precursor composition stored in the reservoir via capillaryaction—or via a micro pump—to the heating element 220 that is in theform of a metal wire coil in this example. As such, the heating elementis in a heating arrangement with the liquid transport element.

In some examples, a microfluidic chip may be embedded in the reservoir218, and the amount and/or mass of aerosol precursor compositiondelivered from the reservoir may be controlled by a micro pump, such asone based on microelectromechanical systems (MEMS) technology. Otherexample implementations of reservoirs and transport elements useful inaerosol delivery devices according to the present disclosure are furtherdescribed herein, and such reservoirs and/or transport elements can beincorporated into devices such as those described herein. In particular,specific combinations of heating members and transport elements asfurther described herein may be incorporated into devices such as thosedescribed herein.

In use, when a user draws on the aerosol delivery device 100, airflow isdetected by the flow sensor 210, and the heating element 220 isactivated to vaporize components of the aerosol precursor composition.Drawing upon the mouth end of the aerosol delivery device causes ambientair to enter the air intake 236 and pass through the cavity 232 in thecoupler 230 and the central opening in the projection 234 of the base228. In the cartridge 104, the drawn air combines with the formed vaporto form an aerosol. The aerosol is whisked, aspirated or otherwise drawnaway from the heating element and out the opening 224 in the mouth endof the aerosol delivery device.

For further detail regarding implementations of an aerosol deliverydevice including a control body and a cartridge in the case of anelectronic cigarette, see the above-cited U.S. patent application Ser.No. 15/836,086 to Sur, and U.S. patent application Ser. No. 15/916,834to Sur et al., as well as U.S. patent application Ser. No. 15/916,696 toSur, filed Mar. 9, 2018, which is also incorporated herein by reference.

FIGS. 3-6 illustrate implementations of an aerosol delivery deviceincluding a control body and an aerosol source member in the case of aheat-not-burn device. More specifically, FIG. 3 illustrates an aerosoldelivery device 300 according to an example implementation of thepresent disclosure. The aerosol delivery device may include a controlbody 302 and an aerosol source member 304. In various implementations,the aerosol source member and the control body can be permanently ordetachably aligned in a functioning relationship. In this regard, FIG. 3illustrates the aerosol delivery device in a coupled configuration,whereas FIG. 4 illustrates the aerosol delivery device in a decoupledconfiguration. Various mechanisms may connect the aerosol source memberto the control body to result in a threaded engagement, a press-fitengagement, an interference fit, a sliding fit, a magnetic engagement,or the like.

As shown in FIG. 4 , in various implementations of the presentdisclosure, the aerosol source member 304 may comprise a heated end 406,which is configured to be inserted into the control body 302, and amouth end 408, upon which a user draws to create the aerosol. In variousimplementations, at least a portion of the heated end may include anaerosol precursor composition 410.

In various implementations, the aerosol source member 304, or a portionthereof, may be wrapped in an exterior overwrap material 412, which maybe formed of any material useful for providing additional structureand/or support for the aerosol source member. In variousimplementations, the exterior overwrap material may comprise a materialthat resists transfer of heat, which may include a paper or otherfibrous material, such as a cellulose material. The exterior overwrapmaterial may also include at least one filler material imbedded ordispersed within the fibrous material. In various implementations, thefiller material may have the form of water insoluble particles.Additionally, the filler material may incorporate inorganic components.In various implementations, the exterior overwrap may be formed ofmultiple layers, such as an underlying, bulk layer and an overlyinglayer, such as a typical wrapping paper in a cigarette. Such materialsmay include, for example, lightweight “rag fibers” such as flax, hemp,sisal, rice straw, and/or esparto. The exterior overwrap may alsoinclude a material typically used in a filter element of a conventionalcigarette, such as cellulose acetate. Further, an excess length of theoverwrap at the mouth end 408 of the aerosol source member may functionto simply separate the aerosol precursor composition 410 from the mouthof a consumer or to provide space for positioning of a filter material,as described below, or to affect draw on the article or to affect flowcharacteristics of the vapor or aerosol leaving the device during draw.Further discussion relating to the configurations for overwrap materialsthat may be used with the present disclosure may be found in theabove-cited U.S. Pat. No. 9,078,473 to Worm et al.

In various implementations other components may exist between theaerosol precursor composition 410 and the mouth end 408 of the aerosolsource member 304, wherein the mouth end may include a filter 414, whichmay, for example, be made of a cellulose acetate or polypropylenematerial. The filter may additionally or alternatively contain strandsof tobacco containing material, such as described in U.S. Pat. No.5,025,814 to Raker et al., which is incorporated herein by reference inits entirety. In various implementations, the filter may increase thestructural integrity of the mouth end of the aerosol source member,and/or provide filtering capacity, if desired, and/or provide resistanceto draw. In some implementations one or any combination of the followingmay be positioned between the aerosol precursor composition and themouth end: an air gap; phase change materials for cooling air; flavorreleasing media; ion exchange fibers capable of selective chemicaladsorption; aerogel particles as filter medium; and other suitablematerials.

Various implementations of the present disclosure employ one or moreconductive heating elements to heat the aerosol precursor composition410 of the aerosol source member 304. In various implementations, theheating element may be provided in a variety forms, such as in the formof a foil, a foam, a mesh, a hollow ball, a half ball, discs, spirals,fibers, wires, films, yarns, strips, ribbons, or cylinders. Such heatingelements often comprise a metal material and are configured to produceheat as a result of the electrical resistance associated with passing anelectrical current therethrough. Such resistive heating elements may bepositioned in direct contact with, or in proximity to, the aerosolsource member and particularly, the aerosol precursor composition of theaerosol source member 304. The heating element may be located in thecontrol body and/or the aerosol source member. In variousimplementations, the aerosol precursor composition may includecomponents (i.e., heat conducting constituents) that are imbedded in, orotherwise part of, the substrate portion that may serve as, orfacilitate the function of, the heating assembly. Some examples ofvarious heating members and elements are described in U.S. Pat. No.9,078,473 to Worm et al.

Some non-limiting examples of various heating element configurationsinclude configurations in which a heating element is placed in proximitywith the aerosol source member 304. For instance, in some examples, atleast a portion of a heating element may surround at least a portion ofan aerosol source member. In other examples, one or more heatingelements may be positioned adjacent an exterior of an aerosol sourcemember when inserted in the control body 302. In other examples, atleast a portion of a heating element may penetrate at least a portion ofan aerosol source member (such as, for example, one or more prongsand/or spikes that penetrate an aerosol source member), when the aerosolsource member is inserted into the control body. In some instances, theaerosol precursor composition may include a structure in contact with,or a plurality of beads or particles imbedded in, or otherwise part of,the aerosol precursor composition that may serve as, or facilitate thefunction of the heating element.

FIG. 5 illustrates a front view of an aerosol delivery device 300according to an example implementation of the present disclosure, andFIG. 6 illustrates a sectional view through the aerosol delivery deviceof FIG. 5 . In particular, the control body 302 of the depictedimplementation may comprise a housing 516 that includes an opening 518defined in an engaging end thereof, a flow sensor 520 (e.g., a puffsensor or pressure switch), a control component 522 (e.g., processingcircuitry, etc.), a power source 524 (e.g., battery, supercapacitor),and an end cap that includes an indicator 526 (e.g., a LED).

In one implementation, the indicator 526 may comprise one or more LEDs,quantum dot-based LEDs or the like. The indicator can be incommunication with the control component 522 and be illuminated, forexample, when a user draws on the aerosol source member 304, whencoupled to the control body 302, as detected by the flow sensor 520.

The control body 302 of the depicted implementation includes one or moreheating assemblies 528 (individually or collectively referred to aheating assembly) configured to heat the aerosol precursor composition410 of the aerosol source member 304. Although the heating assembly ofvarious implementations of the present disclosure may take a variety offorms, in the particular implementation depicted in FIGS. 5 and 6 , theheating assembly comprises an outer cylinder 530 and a heating element532, which in this implementation comprises a plurality of heater prongsthat extend from a receiving base 534 (in various configurations, theheating assembly or more specifically the heater prongs may be referredto as a heater). In the depicted implementation, the outer cylindercomprises a double-walled vacuum tube constructed of stainless steel soas to maintain heat generated by the heater prongs within the outercylinder, and more particularly, maintain heat generated by heaterprongs within the aerosol precursor composition. In variousimplementations, the heater prongs may be constructed of one or moreconductive materials, including, but not limited to, copper, aluminum,platinum, gold, silver, iron, steel, brass, bronze, graphite, or anycombination thereof.

As illustrated, the heating assembly 528 may extend proximate anengagement end of the housing 516, and may be configured tosubstantially surround a portion of the heated end 406 of the aerosolsource member 304 that includes the aerosol precursor composition 410.In such a manner, the heating assembly may define a generally tubularconfiguration. As illustrated in FIGS. 5 and 6 , the heating element 532(e.g., plurality of heater prongs) is surrounded by the outer cylinder530 to create a receiving chamber 536. In such a manner, in variousimplementations the outer cylinder may comprise a nonconductiveinsulating material and/or construction including, but not limited to,an insulating polymer (e.g., plastic or cellulose), glass, rubber,ceramic, porcelain, a double-walled vacuum structure, or anycombinations thereof.

In some implementations, one or more portions or components of theheating assembly 528 may be combined with, packaged with, and/orintegral with (e.g., embedded within) the aerosol precursor composition410. For example, in some implementations the aerosol precursorcomposition may be formed of a material as described above and mayinclude one or more conductive materials mixed therein. In some of theseimplementations, contacts may be connected directly to the aerosolprecursor composition such that, when the aerosol source member isinserted into the receiving chamber of the control body, the contactsmake electrical connection with the electrical energy source.Alternatively, the contacts may be integral with the electrical energysource and may extend into the receiving chamber such that, when theaerosol source member is inserted into the receiving chamber of thecontrol body, the contacts make electrical connection with the aerosolprecursor composition. Because of the presence of the conductivematerial in the aerosol precursor composition, the application of powerfrom the electrical energy source to the aerosol precursor compositionallows electrical current to flow and thus produce heat from theconductive material. Thus, in some implementations the heating elementmay be described as being integral with the aerosol precursorcomposition. As a non-limiting example, graphite or other suitable,conductive material may be mixed with, embedded in, or otherwise presentdirectly on or within the material forming the aerosol precursorcomposition to make the heating element integral with the medium.

As noted above, in the illustrated implementation, the outer cylinder530 may also serve to facilitate proper positioning of the aerosolsource member 304 when the aerosol source member is inserted into thehousing 516. In various implementations, the outer cylinder of theheating assembly 528 may engage an internal surface of the housing toprovide for alignment of the heating assembly with respect to thehousing. Thereby, as a result of the fixed coupling between the heatingassembly, a longitudinal axis of the heating assembly may extendsubstantially parallel to a longitudinal axis of the housing. Inparticular, the support cylinder may extend from the opening 518 of thehousing to the receiving base 534 to create the receiving chamber 536.

The heated end 406 of the aerosol source member 304 is sized and shapedfor insertion into the control body 302. In various implementations, thereceiving chamber 536 of the control body may be characterized as beingdefined by a wall with an inner surface and an outer surface, the innersurface defining the interior volume of the receiving chamber. Forexample, in the depicted implementations, the outer cylinder 530 definesan inner surface defining the interior volume of the receiving chamber.In the illustrated implementation, an inner diameter of the outercylinder may be slightly larger than or approximately equal to an outerdiameter of a corresponding aerosol source member (e.g., to create asliding fit) such that the outer cylinder is configured to guide theaerosol source member into the proper position (e.g., lateral position)with respect to the control body. Thus, the largest outer diameter (orother dimension depending upon the specific cross-sectional shape of theimplementations) of the aerosol source member may be sized to be lessthan the inner diameter (or other dimension) at the inner surface of thewall of the open end of the receiving chamber in the control body. Insome implementations, the difference in the respective diameters may besufficiently small so that the aerosol source member fits snugly intothe receiving chamber, and frictional forces prevent the aerosol sourcemember from being moved without an applied force. On the other hand, thedifference may be sufficient to allow the aerosol source member to slideinto or out of the receiving chamber without requiring undue force.

In the illustrated implementation, the control body 302 is configuredsuch that when the aerosol source member 304 is inserted into thecontrol body, the heating element 532 (e.g., heater prongs) is locatedin the approximate radial center of at least a portion of the aerosolprecursor composition 410 of the heated end 406 of the aerosol sourcemember. In such a manner, when used in conjunction with a solid orsemi-solid aerosol precursor composition, the heater prongs may be indirect contact with the aerosol precursor composition. In otherimplementations, such as when used in conjunction with an extrudedaerosol precursor composition that defines a tube structure, the heaterprongs may be located inside of a cavity defined by an inner surface ofthe extruded tube structure, and would not contact the inner surface ofthe extruded tube structure.

During use, the consumer initiates heating of the heating assembly 528,and in particular, the heating element 532 that is adjacent the aerosolprecursor composition 410 (or a specific layer thereof). Heating of theaerosol precursor composition releases the inhalable substance withinthe aerosol source member 304 so as to yield the inhalable substance.When the consumer inhales on the mouth end 408 of the aerosol sourcemember, air is drawn into the aerosol source member through an airintake 538 such as openings or apertures in the control body 302. Thecombination of the drawn air and the released inhalable substance isinhaled by the consumer as the drawn materials exit the mouth end of theaerosol source member. In some implementations, to initiate heating, theconsumer may manually actuate a pushbutton or similar component thatcauses the heating element of the heating assembly to receive electricalenergy from the battery or other energy source. The electrical energymay be supplied for a pre-determined length of time or may be manuallycontrolled.

In some implementations, flow of electrical energy does notsubstantially proceed in between puffs on the device 300 (althoughenergy flow may proceed to maintain a baseline temperature greater thanambient temperature—e.g., a temperature that facilitates rapid heatingto the active heating temperature). In the depicted implementation,however, heating is initiated by the puffing action of the consumerthrough use of one or more sensors, such as flow sensor 520. Once thepuff is discontinued, heating will stop or be reduced. When the consumerhas taken a sufficient number of puffs so as to have released asufficient amount of the inhalable substance (e.g., an amount sufficientto equate to a typical smoking experience), the aerosol source member304 may be removed from the control body 302 and discarded. In someimplementations, further sensing elements, such as capacitive sensingelements and other sensors, may be used as discussed in U.S. patentapplication Ser. No. 15/707,461 to Phillips et al., which isincorporated herein by reference.

In various implementations, the aerosol source member 304 may be formedof any material suitable for forming and maintaining an appropriateconformation, such as a tubular shape, and for retaining therein theaerosol precursor composition 410. In some implementations, the aerosolsource member may be formed of a single wall or, in otherimplementations, multiple walls, and may be formed of a material(natural or synthetic) that is heat resistant so as to retain itsstructural integrity—e.g., does not degrade—at least at a temperaturethat is the heating temperature provided by the electrical heatingelement, as further discussed herein. While in some implementations, aheat resistant polymer may be used, in other implementations, theaerosol source member may be formed from paper, such as a paper that issubstantially straw-shaped. As further discussed herein, the aerosolsource member may have one or more layers associated therewith thatfunction to substantially prevent movement of vapor therethrough. In oneexample implementation, an aluminum foil layer may be laminated to onesurface of the aerosol source member. Ceramic materials also may beused. In further implementations, an insulating material may be used soas not to unnecessarily move heat away from the aerosol precursorcomposition. Further example types of components and materials that maybe used to provide the functions described above or be used asalternatives to the materials and components noted above can be those ofthe types set forth in U.S. Pat. App. Pub. Nos. 2010/00186757 to Crookset al., 2010/00186757 to Crooks et al., and 2011/0041861 to Sebastian etal., all of which are incorporated herein by reference.

In the depicted implementation, the control body 302 includes a controlcomponent 522 that controls the various functions of the aerosoldelivery device 300, including providing power to the electrical heatingelement 532. For example, the control component may include processingcircuitry (which may be connected to further components, as furtherdescribed herein) that is connected by electrically conductive wires(not shown) to the power source 524. In various implementations, theprocessing circuitry may control when and how the heating assembly 528,and particularly the heater prongs, receives electrical energy to heatthe aerosol precursor composition 410 for release of the inhalablesubstance for inhalation by a consumer. In some implementations, suchcontrol may be activated by a flow sensor 520 as described in greaterdetail above.

As seen in FIGS. 5 and 6 , the heating assembly 528 of the depictedimplementation comprises an outer cylinder 530 and a heating element 532(e.g., plurality of heater prongs) that extend from a receiving base534. In some implementations, such as those wherein the aerosolprecursor composition 410 comprises a tube structure, the heater prongsmay be configured to extend into a cavity defined by the inner surfaceof the aerosol precursor composition. In other implementations, such asthe depicted implementation wherein the aerosol precursor compositioncomprises a solid or semi-solid, the plurality of heater prongs areconfigured to penetrate into the aerosol precursor composition containedin the heated end 406 of the aerosol source member 304 when the aerosolsource member is inserted into the control body 302. In suchimplementations, one or more of the components of the heating assembly,including the heater prongs and/or the receiving base, may beconstructed of a non-stick or stick-resistant material, for example,certain aluminum, copper, stainless steel, carbon steel, and ceramicmaterials. In other implementations, one or more of the components ofthe heating assembly, including the heater prongs and/or the receivingbase, may include a non-stick coating, including, for example, apolytetrafluoroethylene (PTFE) coating, such as Teflon®, or othercoatings, such as a stick-resistant enamel coating, or a ceramiccoating, such as Greblon®, or Thermolon™, or a ceramic coating, such asGreblon®, or Thermolon™.

In addition, although in the depicted implementation there are multipleheater prongs 532 that are substantially equally distributed about thereceiving base 534, it should be noted that in other implementations,any number of heater prongs may be used, including as few as one, withany other suitable spatial configuration. Furthermore, in variousimplementations the length of the heater prongs may vary. For example,in some implementations the heater prongs may comprise smallprojections, while in other implementations the heater prongs may extendany portion of the length of the receiving chamber 536, including up toabout 25%, up to about 50%, up to about 75%, and up to about the fulllength of the receiving chamber. In still other implementations, theheating assembly 528 may take on other configurations. Examples of otherheater configurations that may be adapted for use in the presentinvention per the discussion provided above can be found in U.S. Pat.No. 5,060,671 to Counts et al., U.S. Pat. No. 5,093,894 to Deevi et al.,U.S. Pat. No. 5,224,498 to Deevi et al., U.S. Pat. No. 5,228,460 toSprinkel Jr., et al., U.S. Pat. No. 5,322,075 to Deevi et al., U.S. Pat.No. 5,353,813 to Deevi et al., U.S. Pat. No. 5,468,936 to Deevi et al.,U.S. Pat. No. 5,498,850 to Das, U.S. Pat. No. 5,659,656 to Das, U.S.Pat. No. 5,498,855 to Deevi et al., U.S. Pat. No. 5,530,225 toHajaligol, U.S. Pat. No. 5,665,262 to Hajaligol, U.S. Pat. No. 5,573,692to Das et al.; and U.S. Pat. No. 5,591,368 to Fleischhauer et al., whichare incorporated herein by reference.

In various implementations, the control body 302 may include an airintake 538 (e.g., one or more openings or apertures) therein forallowing entrance of ambient air into the interior of the receivingchamber 536. In such a manner, in some implementations the receivingbase 534 may also include an air intake. Thus, in some implementationswhen a consumer draws on the mouth end of the aerosol source member 304,air can be drawn through the air intake of the control body and thereceiving base into the receiving chamber, pass into the aerosol sourcemember, and be drawn through the aerosol precursor composition 410 ofthe aerosol source member for inhalation by the consumer. In someimplementations, the drawn air carries the inhalable substance throughthe optional filter 414 and out of an opening at the mouth end 408 ofthe aerosol source member. With the heating element 532 positionedinside the aerosol precursor composition, the heater prongs may beactivated to heat the aerosol precursor composition and cause release ofthe inhalable substance through the aerosol source member.

As described above with reference to FIGS. 5 and 6 in particular,various implementations of the present disclosure employ a conductiveheater to heat the aerosol precursor composition 410. As also indicatedabove, various other implementations employ an induction heater to heatthe aerosol precursor composition. In some of these implementations, theheating assembly 528 may be configured as an induction heater thatcomprises a transformer with an induction transmitter and an inductionreceiver. In implementations in which the heating assembly is configuredas the induction heater, the outer cylinder 530 may be configured as theinduction transmitter, and the heating element 532 (e.g., plurality ofheater prongs) that extend from the receiving base 534 may be configuredas the induction receiver. In various implementations, one or both ofthe induction transmitter and induction receiver may be located in thecontrol body 302 and/or the aerosol source member 304.

In various implementations, the outer cylinder 530 and heating element532 as the induction transmitter and induction receiver may beconstructed of one or more conductive materials, and in furtherimplementations the induction receiver may be constructed of aferromagnetic material including, but not limited to, cobalt, iron,nickel, and combinations thereof. In one example implementation, thefoil material is constructed of a conductive material and the heaterprongs are constructed of a ferromagnetic material. In variousimplementations, the receiving base may be constructed of anon-conductive and/or insulating material.

The outer cylinder 530 as the induction transmitter may include alaminate with a foil material that surrounds a support cylinder. In someimplementations, the foil material may include an electrical traceprinted thereon, such as, for example, one or more electrical tracesthat may, in some implementations, form a helical coil pattern when thefoil material is positioned around the heating element 532 as theinduction receiver. The foil material and support cylinder may eachdefine a tubular configuration. The support cylinder may be configuredto support the foil material such that the foil material does not moveinto contact with, and thereby short-circuit with, the heater prongs. Insuch a manner, the support cylinder may comprise a nonconductivematerial, which may be substantially transparent to an oscillatingmagnetic field produced by the foil material. In variousimplementations, the foil material may be imbedded in, or otherwisecoupled to, the support cylinder. In the illustrated implementation, thefoil material is engaged with an outer surface of the support cylinder;however, in other implementations, the foil material may be positionedat an inner surface of the support cylinder or be fully imbedded in thesupport cylinder.

The foil material of the outer cylinder 530 may be configured to createan oscillating magnetic field (e.g., a magnetic field that variesperiodically with time) when alternating current is directed through it.The heater prongs of the heating element 532 may be at least partiallylocated or received within the outer cylinder and include a conductivematerial. By directing alternating current through the foil material,eddy currents may be generated in the heater prongs via induction. Theeddy currents flowing through the resistance of the material definingthe heater prongs may heat it by Joule heating (i.e., through the Jouleeffect). The heater prongs may be wirelessly heated to form an aerosolfrom the aerosol precursor composition 410 positioned in proximity tothe heater prongs.

FIG. 7 illustrates a sectional view of an aerosol delivery device 700according to another example implementation. The aerosol delivery device700 of FIG. 7 is similar to the aerosol delivery device 300 of FIGS. 3-6, and is particularly suited for segmented heating of the aerosolprecursor composition 410. The aerosol delivery device 700 includes acontrol body 702 similar to control body 302 but including one or moreheating assemblies 728 (individually or collectively referred to aheating assembly) configured to heat the aerosol precursor compositionof the aerosol source member 304.

In the particular implementation depicted in FIG. 7 , the heatingassembly comprises an outer cylinder 530 and a segmented heater 730including a plurality of heating elements 732 such as a plurality ofelectrically-conductive prongs (heater prongs) that are physicallyseparate and spaced apart from one another. In some examples, each prongof the plurality of electrically-conductive prongs is a heating elementof the plurality of heating elements of the segmented heater. In anotherexample, the plurality of heating elements may be or includephysically-isolated resistive heating elements that may be positionedadjacent respective exterior surface regions of the aerosol sourcemember. In yet another example, the plurality of heating elements may beor include physically-isolated coils capable of producinglocalized/regionalized eddy currents in respective sections of theaerosol source member.

In examples in which the plurality of heating elements 732 are aplurality of heater prongs, these heater prongs may extend along andradially inward from an inner surface of the outer cylinder 330, andthereby lengthwise along the aerosol precursor composition 410. In thedepicted implementation, the outer cylinder comprises a double-walledvacuum tube constructed of stainless steel so as to maintain heatgenerated by the heating elements (e.g., heater prongs) within the outercylinder, and more particularly, maintain heat generated by heatingelements within the aerosol precursor composition. Similar to above, invarious implementations, the heating elements may be constructed of oneor more conductive materials, including, but not limited to, copper,aluminum, platinum, gold, silver, iron, steel, brass, bronze, graphite,or any combination thereof.

In some examples the heating elements 732 of the segmented heater 730may be powerable to heat a plurality of sections of the aerosolprecursor composition 410. The heating elements may be concurrentlypowered to heat respective sections of the plurality of sections of theaerosol precursor composition. In some examples, heating elements of theplurality of heating elements may be separately powerable. In some ofthese examples, one or more of the heating elements may be separatelypowered to heat respective one or more sections of the plurality ofsections of the aerosol precursor composition, and any other heatingelements of the plurality of heating elements being simultaneouslyunpowered.

Other implementations of the aerosol delivery device, control body andaerosol source member are described in the above-cited U.S. patentapplication Ser. No. 15/916,834 to Sur et al., U.S. patent applicationSer. No. 15/916,696 to Sur, U.S. patent application Ser. No. 15/836,086to Sur, and U.S. patent application Ser. No. 15/976,526 to Sur, all ofwhich are incorporated herein by reference.

FIGS. 8 and 9 illustrate implementations of an aerosol delivery deviceincluding a control body and a cartridge in the case of ano-heat-no-burn device. In this regard, FIG. 8 illustrates a side viewof an aerosol delivery device 800 including a control body 802 and acartridge 804, according to various example implementations of thepresent disclosure. In particular, FIG. 8 illustrates the control bodyand the cartridge coupled to one another. The control body and thecartridge may be detachably aligned in a functioning relationship.

FIG. 9 more particularly illustrates the aerosol delivery device 800, inaccordance with some example implementations. As seen in the cut-awayview illustrated therein, again, the aerosol delivery device cancomprise a control body 802 and a cartridge 804 each of which include anumber of respective components. The components illustrated in FIG. 9are representative of the components that may be present in a controlbody and cartridge and are not intended to limit the scope of componentsthat are encompassed by the present disclosure. As shown, for example,the control body can be formed of a control body housing or shell 906that can include a control component 908 (e.g., processing circuitry,etc.), an input device 910, a power source 912 and an indicator 914(e.g., LED, quantum dot-based LED), and such components can be variablyaligned. Here, a particular example of a suitable control componentincludes the PIC16(L)F1713/6 microcontrollers from Microchip TechnologyInc., which is described in Microchip Technology, Inc., AN2265,Vibrating Mesh Nebulizer Reference Design (2016), which is incorporatedby reference.

The cartridge 804 can be formed of a housing—referred to at times as acartridge shell 916—enclosing a reservoir 918 configured to retain theaerosol precursor composition, and including a nozzle 920 with anaerosol production component having no-heat-no-burn atomizingtechnology. This technology, in some examples, is a piezo-basedtechnology such as a mesh, ultrasonic, or surface acoustic wavetechnology. In some more particular examples, the nozzle has an aerosolproduction component in the form of at least onepiezoelectric/piezomagnetic mesh. Similar to above, in variousconfigurations, this structure may be referred to as a tank; andaccordingly, the terms “cartridge,” “tank” and the like may be usedinterchangeably to refer to a shell or other housing enclosing areservoir for aerosol precursor composition, and including a nozzle.

The reservoir 918 illustrated in FIG. 9 can be a container or can be afibrous reservoir, as presently described. The reservoir may be in fluidcommunication with the nozzle 920 for transport of an aerosol precursorcomposition stored in the reservoir housing to the nozzle. An opening922 may be present in the cartridge shell 916 (e.g., at the mouthend) toallow for egress of formed aerosol from the cartridge 804.

In some examples, a transport element may be positioned between thereservoir 918 and nozzle 920, and configured to control an amount ofaerosol precursor composition passed or delivered from the reservoir tothe nozzle. In some examples, a microfluidic chip may be embedded in thecartridge 804, and the amount and/or mass of aerosol precursorcomposition delivered from the reservoir may be controlled by one ormore microfluidic components. One example of a microfluidic component isa micro pump 924, such as one based on microelectromechanical systems(MEMS) technology. Examples of suitable micro pumps include the modelMDP2205 micro pump and others from thinXXS Microtechnology AG, the mp5and mp6 model micro pumps and others from Bartels Mikrotechnik GmbH, andpiezoelectric micro pumps from Takasago Fluidic Systems.

As also shown, in some examples, a micro filter 926 may be positionedbetween the micro pump 924 and nozzle 920 to filter aerosol precursorcomposition delivered to the nozzle. Like the micro pump, the microfilter is a microfluidic component. Examples of suitable micro filtersinclude flow-through micro filters those manufactured usinglab-on-a-chip (LOC) techniques.

In use, when the input device 910 detects user input to activate theaerosol delivery device, the piezoelectric/piezomagnetic mesh isactivated to vibrate and thereby draw aerosol precursor compositionthrough the mesh. This forms droplets of aerosol precursor compositionthat combine with air to form an aerosol. The aerosol is whisked,aspirated or otherwise drawn away from the mesh and out the opening 922in the mouthend of the aerosol delivery device.

The aerosol delivery device 800 can incorporate the input device 910such as a switch, sensor or detector for control of supply of electricpower to the at least one piezoelectric/piezomagnetic mesh of the nozzle920 when aerosol generation is desired (e.g., upon draw during use). Assuch, for example, there is provided a manner or method of turning offpower to the mesh when the aerosol delivery device is not being drawnupon during use, and for turning on power to actuate or trigger theproduction and dispensing of aerosol from the nozzle during draw.Additional representative types of sensing or detection mechanisms,structure and configuration thereof, components thereof, and generalmethods of operation thereof, are described above and in U.S. Pat. No.5,261,424 to Sprinkel, Jr., U.S. Pat. No. 5,372,148 to McCafferty etal., and PCT Pat. App. Pub. No. WO 2010/003480 to Flick, all of whichare incorporated herein by reference.

For more information regarding the above and other implementations of anaerosol delivery device in the case of a no-heat-no-burn device, seeU.S. patent application Ser. No. 15/651,548 to Sur, filed Jul. 17, 2017,which is incorporated herein by reference.

As described above, the aerosol delivery device of exampleimplementations may include various electronic components in the contextof an electronic cigarette, heat-not-burn device or no-heat-no-burndevice, or even in the case of a device that includes the functionalityof one or more of an electronic cigarette, heat-not-burn device orno-heat-no-burn device. FIG. 10 illustrates a circuit diagram ofcircuitry 1000 that may be implemented on and/or incorporatefunctionality of any one or more of aerosol delivery devices 100, 300,700, 800 according to various example implementations of the presentdisclosure. In some more particular examples, the circuit diagramillustrates circuitry that may be implemented on and/or incorporatefunctionality of any one or more of control body 102, 302, 702 or 802.Additionally or alternatively, in some examples, the circuit diagram isof circuitry that may be implemented on a cartridge of an aerosoldelivery device, such as cartridge 104, 804.

As shown in FIG. 10 , the circuitry 1000 includes a control component1004 (with processing circuitry 1006) and a power source 1008 that maycorrespond to or include functionality of respective ones of the controlbody 102, 302, 702, 802, control component 208, 522, 908, and powersource 212, 524, 912. The circuitry also includes an aerosol productioncomponent 1010 that may correspond to or include functionality ofheating element 220, 532, or piezo-based aerosol production component(e.g., piezoelectric/piezomagnetic mesh) of nozzle 920. In someimplementations, circuitry includes terminals 1012 configured to connectthe power source 1004. The circuitry may include the aerosol productioncomponent or second terminals 1014 configured to connect the aerosolproduction component.

In some examples, the circuitry 1000 includes a sensor 1016 maycorrespond to or include functionality of sensor 210, 520, or inputdevice 910. The sensor may be a pressure sensor configured to producemeasurements of pressure caused by a flow of air through at least aportion of the aerosol delivery device, or otherwise receive input toindicate use of the aerosol delivery device. The sensor may beconfigured to convert the measurements/user input to correspondingelectrical signals, which may include conversion of analog to digital.In some examples, this sensor may be a digital sensor, digital pressuresensor or the like, some suitable examples of which are manufactured byMurata Manufacturing Co., Ltd.

The processing circuitry 1006 may be configured to switchably connectthe power source 1008 to a load 1018 including the aerosol productioncomponent 1010 and thereby power the aerosol production component. Moreparticularly, for example, the processing circuitry may be configured toreceive the corresponding electrical signals from the sensor 1016, andin response connect the power source to the load including the aerosolproduction component and thereby power the aerosol production component.The processing circuitry may be configured to process the correspondingelectrical signals to determine an on/off condition, and may modulateswitching connection of the power source to the load in proportion tothe measurements/user input produced by the sensor. In some examples,the control component 1004 further includes a switch (LS) 1020 betweenthe sensor and the load, and controllable by the processing circuitry toconnect and disconnect the power source to and from the load includingthe aerosol production component.

As also shown in FIG. 10 , in some examples, the circuitry 1000 includesa piezo sensor 1022 operatively coupled with the power source 1008 andthe processing circuitry 1006. The piezo sensor may be configured togenerate an electrical response to a deformation of the power source, inwhich the electrical response is indicative of a characteristic of thedeformation. A characteristic of the deformation may be, in someexamples, an amount of deformation of the power source, and as an amountof the deformation increases or decreases, the electrical responserespectively increases or decreases proportionally. In various examples,the electrical response may indicate a fracture of or within the powersource. Additionally or alternatively, for example, the electricalresponse may indicate at least one of a threshold amount of mechanicalstress, bending, strain, stress, microfractures, shrinkage, or expansionon or of the power source.

The processing circuitry 1006 may be configured to control the aerosoldelivery device based at least in part of the characteristic of thedeformation indicated by the electrical response. In some examples, thecharacteristic of the deformation may be an amount of the deformation.The processing circuitry may also be configured to measure theelectrical response (generated by the piezo sensor 1022) to determinethe amount of the deformation, and control the aerosol delivery devicebased on the measurement of the electrical response. Regarding thiscontrol, the processing circuitry may be configured to disable afunctionality of the aerosol delivery device when the amount of thedeformation is at least a threshold amount, as indicated by theelectrical response. For example, the processing circuitry may beconfigured to lock the aerosol delivery device. Additionally oralternatively, the processing circuitry may be configured to disablecharging or discharging of the power source 1002, disconnect the powersource from the load 1008, and/or provide user-perceptible feedback(e.g., via indicator 914) that indicates a state of the power sourcesuch as whether the power source is on or off, a level of charge of thepower source, and/or a condition of the power source. In some of theseexamples, the user-perceptible feedback includes audio, visual, and/orhaptic feedback that is perceptible to a user via corresponding indicesof operation as previously described.

FIG. 11 is a flowchart illustrating various operations in a method 1100of operating the circuitry 1000 according to example implementations ofthe present disclosure. As shown at block 1102, the method includesswitchably connecting the power source 1008 to a load 1018 including theaerosol production component 1010 and thereby powering the aerosolproduction component to produce an aerosol from an aerosol precursorcomposition. As shown at block 1104, the method includes generating, bythe piezo sensor 1022, an electrical response to a deformation of thepower source, the electrical response indicative of a characteristic ofthe deformation. In some examples, the characteristic of the deformationis an amount of the deformation, and the method 1100 may furthercomprise measuring the electrical response to determine the amount ofthe deformation, as shown at block 1106.

The method also includes controlling the aerosol delivery device basedat least in part on the characteristic of the deformation indicated bythe electrical response, as shown at block 1108. Controlling thecircuitry 1000 may further comprise disabling a functionality of theaerosol delivery device when the amount of the deformation is at least athreshold amount, as shown at block 1110.

In some examples, controlling the circuitry 1000 further comprisescontrolling the aerosol delivery device when the electrical responseindicates a fracture of or within the power source 1008, or indicates atleast one of a threshold amount of mechanical stress, bending,shrinkage, or expansion on or of the power source, as shown at block1112. In some examples controlling the aerosol delivery device furthercomprises one or more of locking the aerosol delivery device, disablingcharging of the power source, disabling discharging of the power source,disconnecting the power source from the load 1018, or providinguser-perceptible feedback (e.g., via indicator 914) regarding a state ofthe power source, as shown at block 1114.

The piezo sensor 1022 may be constructed in any of a number of differentmanners. The piezo sensor may include a piezoelectric materialconfigured to generate an electrical voltage response to the deformationof the power source 1008, a piezoresistive material configured togenerate an electrical resistance response to the deformation of thepower source, or both the piezoelectric material and the piezoresistivematerial.

FIGS. 12A and 12B illustrate examples of piezo sensors 1200 that maycorrespond to piezo sensor 1022, including a piezoelectric material 1202on a core material 1204 (as shown in FIG. 12A) or including thepiezoelectric material surrounding the core material (as shown in FIG.12B). In some of these examples, the core material may be apiezoresistive material. And in some examples, the piezoelectricmaterial on the core material may be formed as a layer of compositematerial 1206.

FIGS. 13A and 13B illustrate examples of a piezo sensor 1300 that maycorrespond to piezo sensor 1022, including a piezoresistive material1302 on a core material 1304 (as shown in FIG. 13A) or including thepiezoresistive material surrounding the core material (as shown in FIG.13B). In some of these examples, the core material may be apiezoelectric material. And similar to FIGS. 12A and 12B, in someexamples, the piezoresistive material on the core material may be formedas a layer of composite material 1306.

In other examples, the core material 1204 or 1304 may be arranged as acenter layer between two layers of piezoelectric material 1202 orpiezoresistive material 1302, respectively. In examples as shown inFIGS. 12B and 13B, the core material 1204 or 1304 may be in the form offibers coated respectively with piezoelectric material 1202 orpiezoresistive material 1302 such that the core material 1204 or 1304 issurrounded by the coated-on piezoelectric material 1202 orpiezoresistive material 1302, respectively.

In the above and other implementations, examples of suitablepiezoelectric material include quartz, gallium phosphate, langasite,lead zirconate titanate, lead titanate, aluminum nitride, lithiumniobate, silicon carbide, zinc oxide nanowires, barium titanate,potassium niobate, bismuth titanate, bismuth sodium titanate, lithiumtantalate, cadmium sulfide, or some polymers such as polyvinylidenedifluoride (PVDF or PVF2). Examples of other piezoresistive materialinclude materials with high sensitivity, such as semiconductormaterials, elastomers, etc. More specifically, examples include: thinplate silicon, doped silicon, crystalline diamond, boron-dopedcrystalline diamond, indium arsenide, indium antimonide, cadmiumtelluride, cadmium, selenide, lead selenide, zinc cadmium selenide, zincsulfide, gallium arsenide, carbon fiber, doped carbon nanowires ornanotubes, conductive fillers such as metal (gold, platinum, etc.), orcarbon filler in non-conductive materials such as PDMS polymers.

In some examples, the core material 1204, 1304 may include carbon fiberor aramid fiber. Carbon fiber has both piezoresistive and piezoelectricproperties and thus can be coated by either piezoresistive orpiezoelectric materials according to whether the carbon fiber as a corematerial is considered to be piezoresistive or piezoelectric for a givenapplication. For examples in which piezoresistive material other thancarbon fiber is used as the core material 1204, the core material may becoated with the piezoelectric material 1202.

The piezoelectric material 1202 or piezoresistive material 1302 may begrown on the surface of the core material 1204 or 1304 using variouschemical synthesis and deposition processes such as hydrothermaldeposition, template-assisted, thermal decomposition, plasma-assistedmethodology, CVD, PVD, electrodeposition, or other vacuum or plasmatechniques of deposition, or different coating methods may be used suchas spray coating, spin coating, sputter coating, dip coating, etc.

In some examples in which the power source 1008 is or includes abattery, the piezo sensor 1022 may be integrated with the battery. FIG.14 illustrates a section-cut of a layer of one or more layers of abattery 1400 that in some examples incorporates the power source 1008and piezo sensor 1022. As shown, the battery includes a housing 1402that contains an electrochemical cell 1404, and a piezo sensor 1406 thatmay correspond to piezo sensor 1022, and thereby piezo sensors 1200,1300. In this regard, the piezo sensor may be embedded within theelectrochemical cell such that the electrochemical cell and piezo sensorare formed in a multilayer arrangement. The electrochemical cell in thismultilayer arrangement may include one or more of each of a number oflayers, such as a cathode layer 1408, an anode layer 1410, and separatorlayers 1412A and 1412B. Separator layer 1412A may be a solid, non-porousseparator. Separator layer 1412B may be between the cathode layer andthe anode layer and may comprise a porous separator (membrane) such as aporous polymer, ceramic, etc. The porosity, material, and thickness ofseparator layer 1412B may be controlled and/or adjusted to tune theion-exchange rate between the cathode layer and the anode layer. Thepiezo sensor may include a layer of composite material 1414, which maycorrespond to the layer of composite material 1206, 1306.

A small change in the structure of the cathode layer 1408, the anode1410, or other parts of the battery 1400 may result in stress or strainin the piezo sensor 1406 that can create a structural change. Thisstructural change may be detected first by the piezoelectric effect thatmay generate electric current upon exposure of the piezo sensor to amechanical stress or tension, and second by a change in the electricalresistance of the layer of composite material, which may be due to adisruption in the connectivity of the layer of composite material. Thedisruption may include changing of the electrical properties of aconductive or semi-conductive material due to the a change in theuniformity (e.g., deformation) of the coating or the core material.Because any change of the shape, length, thickness, other form factorsof the conductive materials, or any deformation or damage (e.g., a bentwire) may result in a change in the electrical properties of thematerials, conductivity and resistance may consequently be affected. Anystress or impact to the battery may result in the deformation (e.g.,bending, strain, microfractures) in the cathode or anode layers of thebattery. Since the piezo sensor comprises self-sensing layers (e.g.,thin conformal layers that may be attached to the anode and cathodelayers), the abovementioned stress or impact may be transferred to theself-sensing layers. This may result in a piezoelectric orpiezoresistive effect that generates an electrical response that may bemeasured by processing circuitry 1006.

This piezoelectric or piezoresistive effect may occur due to change inthe crystal structure of the piezoelectric or piezoresistive materials,which may result in change of electric dipole moments in affectedcrystals. This may be detected and sensed by neighboring crystals andeventually cause a reaction by crystalline or semi-crystalline materialin the form of an electrical response/impulse.

The piezo sensor 1406 may include one or more layers of compositematerial, such as one or more layers of composite material 1206, one ormore layers of composite material 1306, or the like. In some examples,the piezo sensor, or in particular a layer of composite material of thepiezo sensor, may be deposited on a substrate 1416, and the cathodelayer 1408 may be deposited on the layer of composite material so thatthe layer of composite material is between the cathode layer and thesubstrate. Additionally or alternatively, a layer of composite materialof the piezo sensor may be deposited on a substrate 1416, and the anodelayer 1410 may be deposited on the layer of composite material so thatthe layer of composite material is between the anode layer and thesubstrate.

FIGS. 15A and 15B are flowcharts illustrating various operations in amethod 1500 of manufacturing a power source 1008 such as power source1008 or more specifically battery 1400, according to exampleimplementations of the present disclosure. As shown at block 1502, themethod includes forming a piezo sensor such as piezo sensor 1406. Asshown at block 1504, the method includes forming the electrochemicalcell 1404 with the piezo sensor embedded therein. As shown at block1506, the method includes encasing the electrochemical cell and thepiezo sensor in the housing 1402 to thereby contain the electrochemicalcell and the piezo sensor.

In some examples, forming the piezo sensor 1406 includes forming thepiezoelectric material 1202 on the core material 1204, as shown at block1508. In some examples, forming the piezoelectric material on the corematerial further includes depositing the piezoelectric material on thecore material, as shown at block 1510.

In some examples, forming the piezo sensor 1406 includes forming thepiezoresistive material 1302 on the core material 1304, as shown atblock 1512. As shown at block 1514, forming the piezoresistive materialon the core material further includes depositing the piezoresistivematerial on the core material.

As shown in FIG. 15B, in some examples, forming the electrochemical cell1404 with the piezo sensor 1406 embedded therein includes forming theelectrochemical cell and the piezo sensor in a multilayer arrangement,as shown at block 1516. As shown at block 1518, the method 1500 includesforming a layer of composite material 1414, which may correspond to thelayer of composite material 1206, 1306, for the piezo sensor includingpiezoelectric material 1202 and/or piezoresistive material 1302. In someof these examples, forming the layer of composite material includesforming the piezoelectric material on a core of piezoresistive material(corresponding to FIG. 11 ). In other of these examples, forming thelayer of composite material includes forming the piezoresistive materialon a core of piezoelectric material (corresponding to FIG. 12 ).

In some examples, forming the electrochemical cell 1404 includesdepositing the layer of composite material 1414 on the substrate 1416,as shown at block 1520, and depositing the cathode layer 1408 on thelayer of composite material so that the layer of composite material isbetween the cathode layer and the substrate, as shown at block 1522.Additionally or alternatively, forming the electrochemical cell may alsoinclude depositing the anode layer 1410 on the layer of compositematerial so that the layer of composite material is between the anodelayer and the substrate, as shown at block 1524.

The foregoing description of use of the article(s) can be applied to thevarious example implementations described herein through minormodifications, which can be apparent to the person of skill in the artin light of the further disclosure provided herein. The abovedescription of use, however, is not intended to limit the use of thearticle but is provided to comply with all necessary requirements ofdisclosure of the present disclosure. Any of the elements shown in thearticle(s) illustrated in FIGS. 1-15B or as otherwise described abovemay be included in an aerosol delivery device according to the presentdisclosure.

Many modifications and other implementations of the disclosure will cometo mind to one skilled in the art to which this disclosure pertainshaving the benefit of the teachings presented in the foregoingdescriptions and the associated figures. Therefore, it is to beunderstood that the disclosure is not to be limited to the specificimplementations disclosed herein and that modifications and otherimplementations are intended to be included within the scope of theappended claims. Although specific terms are employed herein, they areused in a generic and descriptive sense only and not for purposes oflimitation.

What is claimed is:
 1. An aerosol delivery device comprising: a powersource; an aerosol production component powerable to produce an aerosolfrom an aerosol precursor composition; processing circuitry configuredto switchably connect the power source to a load including the aerosolproduction component and thereby power the aerosol production component;and a piezo sensor operatively coupled with the power source and theprocessing circuitry, the piezo sensor configured to generate anelectrical response to a deformation of the power source, the electricalresponse indicative of a characteristic of the deformation, wherein theprocessing circuitry is configured to control the aerosol deliverydevice based at least in part on the characteristic of the deformationindicated by the electrical response.
 2. The aerosol delivery device ofclaim 1, wherein the characteristic of the deformation is an amount ofthe deformation, and wherein the processing circuitry is furtherconfigured to measure the electrical response to determine the amount ofthe deformation and to control the aerosol delivery device to disable afunctionality of the aerosol delivery device when the amount of thedeformation is at least a threshold amount.
 3. The aerosol deliverydevice of claim 1, wherein the processing circuitry is configured tocontrol the aerosol delivery device when the electrical responseindicates a fracture of or within the power source, or indicates atleast one of a threshold amount of mechanical stress, bending,shrinkage, or expansion on or of the power source.
 4. The aerosoldelivery device of claim 1, wherein the processing circuitry configuredto control the aerosol delivery device includes the processing circuitryconfigured to one or more of lock the aerosol delivery device, disablecharging of the power source, disable discharging of the power source,disconnect the power source from the load, or provide user-perceptiblefeedback regarding a state of the power source.
 5. The aerosol deliverydevice of claim 1, wherein the piezo sensor includes a piezoelectricmaterial on a core material, the piezoelectric material configured togenerate an electrical voltage response to the deformation of the powersource.
 6. The aerosol delivery device of claim 5, wherein the corematerial comprises a piezoresistive material configured to generate anelectrical resistance response to the deformation of the power source.7. The aerosol delivery device of claim 1, wherein the piezo sensorincludes a piezoresistive material on a core material, thepiezoresistive material configured to generate an electrical resistanceresponse to the deformation of the power source.
 8. The aerosol deliverydevice of claim 7, wherein the core material comprises a piezoelectricmaterial configured to generate an electrical voltage response to thedeformation of the power source.
 9. The aerosol delivery device of claim1, wherein the power source comprises a battery including a housing thatcontains an electrochemical cell, and that also contains the piezosensor that is configured to generate the electrical response to adeformation of the electrochemical cell and thereby the power source.10. The aerosol delivery device of claim 9, wherein the piezo sensor isembedded within the electrochemical cell.
 11. The aerosol deliverydevice of claim 10, wherein the electrochemical cell and piezo sensorare formed in a multilayer arrangement including a cathode layer, ananode layer, and a separator layer of the electrochemical cell, andincluding a layer of composite material including at least one ofpiezoelectric material or piezoresistive material for the piezo sensor.12. The aerosol delivery device of claim 11, wherein the layer ofcomposite material includes the piezoelectric material on a core ofpiezoresistive material.
 13. The aerosol delivery device of claim 11,wherein the layer of composite material includes the piezoresistivematerial on a core of piezoelectric material.
 14. The aerosol deliverydevice of claim 11, wherein the multilayer arrangement includes thelayer of composite material deposited on a substrate, and the cathodelayer deposited on the layer of composite material so that the layer ofcomposite material is between the cathode layer and the substrate. 15.The aerosol delivery device of claim 11, wherein the multilayerarrangement includes the layer of composite material deposited on asubstrate, and the anode layer deposited on the layer of compositematerial so that the layer of composite material is between the anodelayer and the substrate.
 16. A method of operating an aerosol deliverydevice equipped with a power source, an aerosol production component,and a piezo sensor operatively coupled with the power source, the methodcomprising: switchably connecting the power source to a load includingthe aerosol production component and thereby powering the aerosolproduction component to produce an aerosol from an aerosol precursorcomposition; generating, by the piezo sensor, an electrical response toa deformation of the power source, the electrical response indicative ofa characteristic of the deformation; and controlling the aerosoldelivery device based at least in part on the characteristic of thedeformation indicated by the electrical response.
 17. The method ofclaim 16, wherein the characteristic of the deformation is an amount ofthe deformation, the method further comprising: measuring the electricalresponse to determine the amount of the deformation, and wherein thecontrolling the aerosol delivery device further comprises disabling afunctionality of the aerosol delivery device when the amount of thedeformation is at least a threshold amount.
 18. The method of claim 16,wherein controlling the aerosol delivery device further comprisescontrolling the aerosol delivery device when the electrical responseindicates a fracture of or within the power source, or indicates atleast one of a threshold amount of mechanical stress, bending,shrinkage, or expansion on or of the power source.
 19. The method ofclaim 16, wherein controlling the aerosol delivery device furthercomprises one or more of locking the aerosol delivery device, disablingcharging of the power source, disabling discharging of the power source,disconnecting the power source from the load, or providinguser-perceptible feedback regarding a state of the power source.